a Removing and installing the engine AR01.10-B-2400I.

fm 1

AR01.10-B-2400I.fm Removing and installing the engine 10.10.01

Engine 611.981/983

1 Coolant piping
2 Exhaust pipe (front part)
3 Bracket
4 Retrun line of heating
5 Return line
6 High pressure line
7 Sealing ring
8 Vacuum piping
9 Intake air pipe
10 Fuel line
11 Fuel line
12 Vacuum piping
13 Cooling piping
14 Sealing ring
15 Bolt

D01.10-1102-06
a Removing and installing the engine AR01.10-B-2400I.fm 2

16 Transmission shaft
17 Nut
18 Tachograph transmitter
19 Sealing ring
20 Connector for reversing light, engine
starting and stopping
21 Rear engine cross-member
22 Nut
23 Nut
24 Shift cable
25 Shift cable
26 Battery ground lead
27 Clutch piping
28 Retainer
29 Sealing gasket

D01.10-1103-06
a Removing and installing the engine AR01.10-B-2400I.fm 3

30 Bolt
31 Engine support

32 k Engine removal device

D01.10-1104-06
a Removing and installing the engine AR01.10-B-2400I.fm 4

ed Removing and installing

a Danger! Risk of scalding by hot coolant under pres- Do not remove the cooling system reser- AS20.00-B-0001-01A
sure, when opening the cooling system reser- voir cap (1) when the system´s tempera-
voir cap. ture is above 90 ºC. Should it be
absolutely necessary to remove the
cooling system cap with the engine hot
(above 50 degrees) proceed carefully to
avoid accidents. Cover the cap with a
thick rag and turn it slowly up to the 1st
stáge and let steam out, before remov-
ing it. Wear protective clothing.

p Replace all self locking bolts and nuts.

i When carrying out jobs at 2 (two) column ele-

vator, lock by the rear end of the vehicle.

1 Eliminate the air from the air conditioning sys-

tem.

p When carrying out repair jobs on electrical cir- AH83.30-B-0005-01A

cuits or on air conditioning components, these
must be protected against humidity.

2 Remove the engine hood. AR88.40-B-3000C

3 Detach the set of engine cables at sides of i Do not desconnect starter motor AR15.18-B-1000-02A
vehicle. cables.

4 Drain the coolant. i At radiator. AR20.00-B-1142A

5 Remove the coolant radiator. AR20.20-B-3865I

a Removing and installing the engine AR01.10-B-2400I.fm 5

6 Remove the upper part of the charge air i Plug the air passagesto prevent AR09.41-B-1312A
intake manifold. debris finding its way in.

7 Remove the high pressure line (6) and return i replace the seal rings (7).
line (5) from the power steering hydraulic
pump.

n BA46.30-B-1003-01F

8 Release fuel lines (10) and (11) from their fas- i Replace the clamps.
teners and isassemble them

9 Remove the refrigerant pipe (13) of the air i Replace the sealing gasket.
conditioning system´s air compressor.

10 Remove the vacuum line (8).

11.1 Loosen the coolant flexible pipe of heating i Fast coupling (compress the tabs
return (4) and separate the fast coupling. and remove it).

11.2 Remove the coolant flexible pipe of heating

union (4) at coolant pump.

12 Remove the coolant flexible pipe of heating

union (1) on coolant pipe at cylinder head
side.

13 Remove the intake air flexible pipe (9) at air

cleaner box

14 Remove the vacuum line (12) at turbocharger

capsule.

15 Loosen exhaust pipe front part nuts on

bracket (3).
a Removing and installing the engine AR01.10-B-2400I.fm 6

16 Detach exhaust pipe front part (2) at turbo-

charger.

17 Remove the transmission shaft (16) on output n BA41.10-B-1001-01B

shaft flange.

p Indications relating to transmission shaft i Replace the nuts (17). AH41.10-B-0001-01A

mounting

18 Remove the tachograph transmitter (18) at i Replace the seal ring (19).
the gearbox.

19 Detach the connector (20) on the reversing

light switch and on the engine sterting and
stopping switch.

20 Release the shift cables (24) and (25); to do i Only with G20, G32 gearboxes
so, press down the flanges, unhook them On synchromesh gearboxes detach the
from the support and detach the cables from unions.
the articulation rotulas.

p Make sure the shift cables (24) and

(25) fit in a safe way in the articulation
rotulas.

a Danger! Risk of poisoning by swallowing brake fluid Use only original brake fluid containers AS42.50-B-0001-01A
and by contact or by splashings in the eyes. and of with easy identification. It is rec-
ommended to wear protective clothing
and gloves when handling brakee fluid.

21 Remove the clutch piping (27) support on Plug the clutch piping (27) with a suit-
gearbox, remove the retainer (28) and pull the able plug (brake caliper blleder cap)
clutch cylinder (27).
a Removing and installing the engine AR01.10-B-2400I.fm 7

p Replace the retainer (28) and the

ring seal (29).

p Indications on brake fluid AH42.50-B-0001-01A

22 Remove the grounding cable (26).

23 Loosen the supporting nuts (22) at the gear- n BA22.10-B-1005-01F

box

24 Loosen the nuts (23), slowly lower the engine n BA22.10-B-1004-01F

rear cross-member (21) and remove it.

i The gearbox caixa de mudança is

supported by the rear axle bracket.

25 Adjust the engine removal device (32) to k

remove the engine.

i The fastening bolt, in the 4th groove

(arrow) of the engine removal device
(32).

26 Attach the engine removal device (32) to lift-

ing brackets (arrows) at front and rear ends of
cylinder head.

27 Loosen engine bracket bolts (30) on engine n BA22.10-B-1002-01F

support, on both sides.
a Removing and installing the engine AR01.10-B-2400I.fm 8

i Lower the engine, place it on the

supports (31), install and finger tighten
the bolts (3). Lower engine completely
and tighten bolts (30) to specified
torque.

28 Carefully lift the engine and the gearbox. i Protect the alternator wiring, the
plastic cover and the front transversal
plate.

29 Carry out assembly in reverse order.

30 Blled the air from clutch drive system. i On synchromesh gearboxes G20 AR25.20-B-0070C
and G32.

31 Check cooling system for tightness. AR20.00-B-1010D

32 Fill up the air conditioning system.

33 Bleed the low pressure fuel circuit.

a Danger! Risk of personal injuries and material Make sure the gearbox is in neutral. AS00.00-B-0005-01A
damage when starting the engine with gear- Wear appropriate clothing and watch the
box shifted in gear. Risk of personal injuries hot and running parts of engine.
when carrying out jobs on a hot and running
engine.

34 Check oil tightness i Run engine and allow it to warm-up,

shut if off and check for tightness.

a Danger! Risk of explosion by fuel catching fire. Risk Take away all flammable sources from AS07.16-B-0001-01A
of injuries to skin and eyes by fuel jets. the danger area.
Do not carry out any job on systems
under pressure.
a Removing and installing the engine AR01.10-B-2400I.fm 9

35 Ceck fuel system tightness. i Run engine and allow it to warm-up,

shut if off and check for tightness.

36 Coding the radio receiver, setting the time.

n Engine supports, engine brackets

Number Designation Engine 611.981/983

BA22.10-B-1002-01F Engine bracket on engine front support Nm 83

BA22.10-B-1004-01F Rear engine cross-member on cosole Nm 45

BA22.10-B-1005-01F Rear engine support on gearbox Nm 89

n Transmission shaft

Number Designation Types 690

BA41.10-B-1001-01B Universal joint yoke bolt M10 Nm 70

n Power sterring pump

Number Designation Engine 611.981/983

BA46.30-B-1003-01F Pressure line at hydraulic power steer- Nm 38

ing pump