Remove/install engine - AR01.10-P-2400GZB: Notes
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ENGINE 642 in MODEL 164
| Remove/install | |||
|---|---|---|---|
| Risk of death caused by vehicle slipping or toppling off the lifting platform. | Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof | Keep body parts and limbs well clear of moving parts. | AS00.00-Z-0011-01A | |
| Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices | No fire, sparks, open flames or smoking. Wear acid-resistant gloves and clothing and safety glasses with side guards. Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground. Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers. | AS54.10-Z-0001-01A | |
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| 1 | Disconnect battery ground line | Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery. | AR54.10-P-0003GZ |
| Notes on battery | AH54.10-P-0001-01A | ||
| 2 | Removes strut tower brace | Model 164.8 only Remove strut tower brace from strut tower mounts. |
AR62.30-P-2500GY |
| 3 | Remove engine trim panel | ||
| 4 | Remove air filter housing | Left side | AR09.10-P-1150GZB |
| Right side | AR09.10-P-1150GZC | ||
| 5 | Remove bottom section of soundproofing | AR94.30-P-5300GZ | |
| 6 | Drain coolant at radiator | AR20.00-P-1142GZB | |
| Notes on coolant | AH20.00-N-2080-01A | ||
| 7 | Remove charge air hose upstream of charge air cooler (1) | Check condition of hose clamp; replace if required. | AR09.41-P-8621GZB |
| 8 | Remove engine charge air channel upstream of charge air cooler (2) | AR09.41-P-8623GZB | |
| 9 | Remove charge air hose downstream of charge air cooler (3) | Check condition of hose clamp; replace if required. | AR09.41-P-8625GZB |
| 10 | Remove vacuum line (4) of brake booster at connection for vacuum pump (5) | By pressing both clamps together and detaching vacuum line (4) on vacuum pump (5). | |
| 11 | Detach coolant hoses (6, 7) at the thermostat housing (8) | Check condition of coolant hoses (6, 7), hose clamp and sealing ring; replace if necessary. | |
| 12 | Remove bracket (9) for servo lines on oil pan (10) | *BA46.30-P-1007-01J | |
| 13 | Extract oil from power steering expansion reservoir (13) | *BF46.20-P-1001-01C | |
| Fig 5 | |||
| 14 | Remove banjo bolt (15) for power steering (16) pressure line on power steering pump (17) | *BA46.30-P-1009-01J | |
| Fig 4 | |||
| 15 | Detach hydraulic line (14) at power steering expansion reservoir (13) | *BA46.30-P-1006-01J | |
| Fig 4 | |||
| 16 | Remove poly-V belt | AR13.20-P-0001GZB | |
| 17 | Detach coolant hoses (11, 12) | Inspect condition of coolant hoses (11, 12) and hose clamps; replace if necessary. | |
| 18 | Remove coolant hose (18) on heat exchanger from connection on firewall (19) | Check condition of coolant hose (18) and hose clamp; replace if necessary. | |
| 19 | Remove radiator crossmember (20) | AR62.30-P-2300GZ | |
| 20 | Remove electric fan (21) | AR20.40-P-5000GZB | |
| 21 | Attach guard plate for radiator/condenser | ||
| Guard plate for radiator/condenser | WF58.50-P-0110-01A | ||
| 22 | Disconnect engine wiring harness | Bind together engine wiring harness and lay on engine. | AR01.00-P-2410GZB |
| 23 | Remove complete exhaust system | AR49.10-P-7100GZB | |
| 24 | Remove transmission with torque converter | Seal connections at transmission and at oil cooler lines immediately using stop plugs. Do not buckle or bend removed oil cooler lines. Installation: Replace O-rings. |
|
| *BA27.55-P-1002-01D | |||
| Fig 4 | |||
| 25 | Remove refrigerant compressor (A9) from timing case cover by removing screw/bolts (24) | Disconnect connector on refrigerant compressor (A9). Attach refrigerant compressor (A9) with connected pipe system laterally at bottom of engine compartment. | |
| *BA83.55-P-1001-01R | |||
| Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 26 | Remove fuel lines (22) on the fuel pipes (23) | Collect escaping fuel in a suitable container! Close off connections immediately and fix fuel lines (22) in place on the exhaust manifold using a tie strap. | |
| Fig 4 | |||
| 27 | Remove screw/bolts on front engine mount at front axle carrier | AR22.10-P-1100GZB | |
| 28 | Hook engine hoist with adapter for engine hoist into lifting eyes on engine | Fig 6 | |
| 29 | Lift out engine | Set engine in an horizontal position in stages with engine hoist and run out to the front with engine hoist. | |
| 30 | Install in the reverse order | ||
| 31 | Fill and bleed power steering pump (17) | AR46.30-P-0010GZ | |
| 32 | Fill cooling system | AR20.00-P-1142GZB | |
| 33 | Check cooling system for leaks | If cylinder head gaskets are new, warm up engine first of all to operating temperature otherwise complete filling of the engine with coolant is not assured. | AR20.00-P-1010GZB |
| 34 | Check engine oil level | In order to avoid measurement errors, vehicle must be parked on an even surface. Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level. |
AR18.00-P-3035-01PI |
| *BF18.00-P-1001-01A | |||
| *BF18.00-P-1001-01S | |||
| 35 | Check transmission oil level and correct if necessary | AR27.00-P-0270W | |
| 36 | Read out fault memory and erase if necessary | Stored fault entries which may be caused by disconnecting cables or by simulation during removal and installation or inspection operations, must be erased from the fault memory after work is completed. | AD00.00-P-2000-04A |
POWER STEERING PUMP
| Number | Designation | Model 164.1/8, 251 with engine 642 | |
|---|---|---|---|
| BA46.30-P-1006-01J | Clamp, hydraulic line to power steering pump reservoir | Nm | 2 |
| BA46.30-P-1007-01J | Bolt, power steering pressure line bracket to engine oil pan | Nm | 10 |
| BA46.30-P-1009-01J | Banjo bolt, power steering pressure line to power steering pump | Nm | 45 |
REFRIGERANT COMPRESSOR
| Number | Designation | Model 164.1/8 | |
|---|---|---|---|
| BA83.55-P-1001-01R | Bolt, refrigerant compressor to timing case and left engine support | Nm | 20 |
TRANSMISSION OIL COOLING SYSTEM
| Number | Designation | Transmission 722.9 | |||
|---|---|---|---|---|---|
| BA27.55-P-1002-01D | Bolt, transmission oil line to transmission housing | Banjo Bolt | Stage 1 | Nm | 5 |
| Stage 2 | ∠° | 90 | |||
| Hexalobular bolt | Nm | 12 | |||
STEERING GEAR
| Number | Designation | Model 164 | ||
|---|---|---|---|---|
| BF46.20-P-1001-01C | Power steering | Filling capacity | Liters | ≈1.2 |
| MB steering gear oil | Sheet | BB00.40-P-0236-03A | ||
ENGINE LUBRICATION SYSTEM
| Number | Designation | Engine 642 without particulate filter | ||
|---|---|---|---|---|
| BF18.00-P-1001-01A | Engine oil | Filling capacity (oil and filter change) |
Liters | 8.5 |
| Specifications for Operating Fluids | Sheet | BB00.40-P-0228-03A | ||
| Sheet | BB00.40-P-0228-05A | |||
| Sheet | BB00.40-P-0228-51A | |||
| Sheet | BB00.40-P-0229-03A | |||
| Sheet | BB00.40-P-0229-31A | |||
| Sheet | BB00.40-P-0229-05A | |||
| Sheet | BB00.40-P-0229-51A | |||
ENGINE LUBRICATION SYSTEM
| Number | Designation | Engine 642 with particulate filter | ||
|---|---|---|---|---|
| BF18.00-P-1001-01S | Engine oil | Filling capacity (oil and filter change) |
Liters | 8.5 |
| Specifications for Operating Fluids | Sheet | BB00.40-P-0228-51A | ||
| Sheet | BB00.40-P-0229-31A | |||
| Sheet | BB00.40-P-0229-51A | |||