Remove/install engine with transmission - AR01.10-P-2401GW
ENGINE 157 in MODEL 463
| Remove/install | |||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | ||
| 1 | Set DIRECT SELECT gear selector switch to position "N" and release parking brake | ||
| 2 | Detach ground line from battery | AR54.10-P-0003GW | |
| Notes on battery | AH54.10-P-0001-01A | ||
| 3 | Open engine hood and raise to vertical position | AR88.40-P-1000GG | |
| 4 | Remove both air filter housings | AR09.10-P-1150GW | |
| 5 | Remove both engine air intake ducts | ||
| 6 | Disconnect purge hose on purging switchover valve from purge line (2) | ||
| 7 | Detach vacuum line from vacuum pump (3) and charge air manifold (4) | ||
| 8 | Drain coolant | AR20.00-P-1142GW | |
| Notes on coolant | AH20.00-N-2080-01A | ||
| 9 | Remove radiator for low temperature water circuit | AR09.41-P-6935GW | |
| 10 | Remove radiator | AR20.20-P-3865GW | |
| 11 | Remove fluid reservoir | AR83.30-P-6520GW | |
| 12 | Remove air plenum chamber and water collector | AR83.10-P-9998GW | |
| 13 | Detach refrigerant line (23) from bracket of traction system hydraulic unit and expansion valve (24) | ||
| Remove/install fluid reservoir. | AR83.30-P-6520GW | ||
| *BA83.30-P-1001-01C | |||
| Fig 4 | |||
| 14 | Detach coolant hose (5) from heater shutoff valve (6) | ||
| 15 | Disconnect coolant hose from low-temperature line (7), to do so pull out clamp | ||
| 16 | Detach coolant hose from fitting (8) | ||
| 17 | Detach coolant feed hose from coolant feed line (9) | ||
| 18 | Detach coolant hose from fitting (10) of coolant pump and remove | AR09.41-P-1311-01AL | |
| 19 | Detach coolant hose from fitting (11) of thermostat housing and remove | AR09.41-P-1311-01AL | |
| 20 | Unscrew nut and detach low-temperature line (12) from bracket (13) on timing case cover | ||
| 21 | Release clamp (14), detach low-temperature line (12) and place to one side | ||
| 22 | Detach pressure line of power steering from bracket (15) to engine oil pan | *BA46.30-P-1025-01B | |
| 23 | Detach hydraulic line (16) from power steering pump (17), oil filter housing (18) and bracket (19) on left cylinder head cover | *BA46.30-P-1019-01B | |
| *BA46.30-P-1020-01B | |||
| *BA46.30-P-1021-01B | |||
| 24 | Remove screw/bolt (22) from power steering pump (17) bracket | ||
| 25 | Remove power steering pump (17) from coolant pump and bracket at bottom of timing case cover | AR46.30-P-0500GW | |
| *BA46.30-P-1018-01B | |||
| *BA46.30-P-1023-01B | |||
| 26 | Remove engine hood catch on right or left side | AR88.40-P-3200GW | |
| 27 | Remove left horn | ||
| 28 | Detach cooling line of power steering from left wheel well paneling | AR46.25-P-3010GW | |
| 29 | Detach oil cooling lines (20) from oil filter housing (18) and bracket (19) to left cylinder head cover and place to one side | ||
| *BA18.30-P-1005-01G | |||
| *BA18.30-P-1007-01G | |||
| Fig 4 | |||
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel | No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| 30 | Reduce fuel pressure through service valve | AR07.03-P-1460-01GW | |
| *BA07.03-P-1007-01E | |||
| Fig 5 | |||
| 31 | Detach fuel line (25) from fuel distributor (21) | *BA07.03-P-1001-01E | |
| 32 | Remove ME-SFI [ME] control unit | AR07.08-P-7008GW | |
| 33 | Disconnect engine wiring harness on the vehicle side | AR01.00-P-2410-02GW | |
| 34 | Mount engine suspension lug | AR33.10-P-0105-01GW | |
| *BA01.30-P-1006-01X | |||
| Fig 6 | |||
| 35 | Remove complete exhaust system | AR49.10-P-7000GW | |
| 36 | Detach transmission oil cooling lines (26) from oil cooler thermostat (27) | AR27.10-P-0501-03GW | |
| Fig 4 | |||
| 37 | Detach ground strap between frame and transmission on transmission | *BA27.40-P-1001-01E | |
| 38 | Detach coolant hose (28) from transmission oil heat exchanger (29) | ||
| 39 | Detach drive shaft from transmission output flange of transmission | ||
| *BA41.10-P-1001-01B | |||
| 40 | Detach rear engine mount from crossmember | AR22.10-P-1160GW | |
| 41 | Detach both single-tube engine vibration dampers from the frame | AR22.10-P-1152GW | |
| 42 | Remove screws/bolts of engine mount from frame | AR22.10-P-1260GW | |
| 43 | Slightly raise engine transmission unit at front engine suspension lug | Load regulator |
|
| 44 | Carefully raise engine transmission unit further and then remove | ||
| 45 | Install in the reverse order | ||
| 46 | Check engine oil level; correct if necessary | ||
| 47 | Pour in coolant | AR20.00-P-1142GW | |
| 48 | Inspecting cooling system for leaks | AR20.00-P-1010GW | |
| 49 | Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks | AR83.30-P-1760GW | |
| 50 | Check transmission oil level and correct if necessary | AR27.00-P-0270W | |
| 51 | Read out fault memory using STAR DIAGNOSIS and erase if necessary | AD00.00-P-2000-04A | |
| Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running | Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. |
AS00.00-Z-0005-01A | |
| 52 | Carry out engine test run, checking the engine for leaks and proper operation |
PROPELLER SHAFT
| Number | Designation | Model 463 | |
|---|---|---|---|
| BA41.10-P-1001-01B | Screw/bolt, homokinetic propeller shaft to transmission flange | Nm | 60 |
HOUSING
| Number | Designation | Transmission 722.9 in model 463 | |
|---|---|---|---|
| BA27.40-P-1001-01E | Bolt, automatic transmission to crankcase | Nm | 39 |
POWER STEERING PUMP
| Number | Designation | Model 463.272/273 | |
|---|---|---|---|
| BA46.30-P-1018-01B | Bolt, power steering pump to coolant pump | Nm | 20 |
| BA46.30-P-1019-01B | Bolt, hydraulic line to power steering pump | Nm | 9 |
| BA46.30-P-1020-01B | Bolt, hydraulic line to oil filter housing | Nm | 9 |
| BA46.30-P-1021-01B | Bolt, hydraulic line to bracket | Nm | 9 |
| BA46.30-P-1023-01B | Bolt, bracket for power steering pump to lower bracket | Nm | 20 |
| BA46.30-P-1025-01B | Bolt, pressure line for P/S to bracket for engine oil pan | Nm | 10 |
AIR CONDITIONING
| Number | Designation | Model 463 | |
|---|---|---|---|
| BA83.30-P-1001-01C | Nut on expansion valve | Nm | 10 |
INJECTORS, INJECTION VALVES, LINES
| Number | Designation | Engine 157 | ||
|---|---|---|---|---|
| BA07.03-P-1001-01E | Union nut, fuel line to fuel distributor | Nm | 22 | |
| BA07.03-P-1007-01E | Protective cap on service valve | Plastic | Nm | 2 |
| Metal | Nm | 15 | ||
CYLINDER HEAD
| Number | Designation | Engine 157 | |
|---|---|---|---|
| BA01.30-P-1006-01X | Bolt, lifting eye to cylinder head | Nm | 14 |
OIL COOLING SYSTEM
| Number | Designation | Engine 157 | |
|---|---|---|---|
| BA18.30-P-1005-01G | Screw/bolt, oil cooler line to oil filter housing | Nm | 9 |
| BA18.30-P-1007-01G | Screw/bolt, oil cooler line bracket to cylinder head cover | Nm | 9 |