REMOVAL
Remove oil filter, see OIL FILTER (2008-10) or OIL FILTER (2011-2012)
| CAUTION | Take extra care when handling the component. |
Remove drive flange plate, see CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)
see 9992520 see 9995297 see 9989721
REMOVE
Drain the engine oil. See OIL FILTER (2008-10) or OIL FILTER (2011-2012)
Remove the engine according to: ENGINE - REMOVAL AND INSTALLATION
Remove the following items
- radiator hose
- front auxiliary unit console
- console transmission
- AC-console
- water pipes
Remove the transmission.
Remove the lower screws (these are difficult to access) between the gearbox and engine before removing the engine and gearbox unit. The engine and gearbox unit must be placed on a suitable surface.
Relieve the transmission. Loose the remaining screws and remove the transmission carefully.
Remove the carrier plate/flywheel. See CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)
Install the following items
- see «9992520»(ref-460875-S32052658872012033000000)
- see «9995297»(ref-460875-S21331165912012033000000)
- see «9989721»(ref-460875-S01561744442012033000000)
Mount the engine in a work stand. Bolt down the engine as shown.
Drain the engine oil. See OIL FILTER (2008-10) or OIL FILTER (2011-2012)
Remove the engine according to: ENGINE - REMOVAL AND INSTALLATION
Remove the following items
- radiator hose
- front auxiliary unit console
- console transmission
- AC-console
- water pipes
Remove the transmission.
Remove the lower screws (these are difficult to access) between the gearbox and engine before removing the engine and gearbox unit. The engine and gearbox unit must be placed on a suitable surface.
Relieve the transmission. Loose the remaining screws and remove the transmission carefully.
Remove the carrier plate/flywheel. See CARRIER PLATE (2008-2009) or CARRIER PLATE (2010-12)
Install the following items
- see «9992520»(ref-460875-S32052658872012033000000)
- see «9995297»(ref-460875-S21331165912012033000000)
- see «9989721»(ref-460875-S01561744442012033000000)
Mount the engine in a work stand. Bolt down the engine as shown.
INSTALLATION
Install cylinder head, see CYLINDER HEAD
Install cylinder head, see CYLINDER HEAD (B6304T4) , CYLINDER HEAD (B6324S5) or CYLINDER HEAD (B6324S4)
Note. Note the position of each component before removal.
Scheme 23
Scheme 24
Scheme 25
Scheme 26
| CAUTION | Take extra care not to damage the mating faces. |
Note. Note the position of each component before removal.
Scheme 27
| CAUTION | Take extra care not to damage the mating faces. |
| CAUTION | The components are paired. If one component is damaged, both components shall be replaced at the same time. |
Remove the following items
- Gasket, inner timing cover, see «GASKET, INNER TIMING COVER»(ref-495375-S23601271682012082100000)
- alternator, see «ALTERNATOR AND REGULATOR - REMOVAL, REPLACEMENT AND INSTALLATION»(ref-495394)
Scheme 28
Scheme 29
Scheme 30
| CAUTION | The components are paired. If one component is damaged, both components shall be replaced at the same time. |
| CAUTION | Take extra care when handling the components. |
see 9995670
Scheme 31
| CAUTION | Take extra care when handling the components. |
see 9997315
Scheme 32
Scheme 33
Scheme 34
see 9997258
Scheme 35
see 9997259
Scheme 36
Scheme 37
Scheme 38
Note. This step requires considerable force.
see 9997317 see 9997329
Scheme 39
Scheme 40
see 9997318 see 9997328 see 9997319
Scheme 41
see 9997320 see 9997337 see 9997319
Scheme 42
see 9997322 see 9997337 see 9997321
Scheme 43
Note. Make sure that the protective cover remains installed.
Note. Make sure that a new component is installed.
see 9997324 see 9997337 see 9997323
Scheme 44
see 9997325 see 9997337 see 9997326
Scheme 45
| CAUTION | Make sure that the area around the component is clean and free of foreign material. |
Use: Cleaning agent, 1161721
Scheme 46
| CAUTION | Make sure that the area around the component is clean and free of foreign material. |
Use: Cleaning agent, 1161721
| CAUTION | Touching the adhesive surface will impair rebonding. |
Use: Metal adhesive, 1161722
Scheme 47
see 9997328 see 9997318 see 9997327
Scheme 48
Scheme 49
Torque: Chain wheel
400 Nm
see 9997317 see 9997329
Scheme 50
| CAUTION | Take extra care when handling the component. |
see 9997316
Scheme 51
Scheme 52
Note. Make sure that the mating faces are clean and free of foreign material.
Note. The component must be installed within 5 minutes of applying the sealant.
Use: Chemical gasket, 1161771
Scheme 53
Torque: Gear housing
Stage 1: 10 Nm
Stage 2: 24 Nm
Scheme 54
Note. Make sure that the mating faces are clean and free of foreign material.
- Use: Chemical gasket, 1161771
Scheme 55
Note. Use a new seal.
see 9997260
see 9997258
Torque: Intermediate shaft alternator side
40 Nm
Torque: M6
10 Nm
Expose the engine according to engine block, exposing
Remove the following items
- oil pump and line. See «OIL PUMP AND LINE (B6324S/2; 2008-10)»(ref-495630-S36738271502012082100000) , «OIL PUMP AND LINE (B6304T2; 2009-10)»(ref-495630-S11702382112012082100000) or «OIL PUMP AND LINE (B6304T4; B6324S4; B6324S5; 2011-12)»(ref-495630-S30664012852012082100000) .
- front crankshaft seal. See «CRANKSHAFT FRONT SEAL»(ref-495375-S35229623872012082100000)
Scheme 56
Scheme 57
see 9997257
Turn the crankshaft so that the piston for cylinder 1 ends up in lower dead center (LDC). Check that there are markings on caps and connecting rods and note which way the marking is located (exhaust/inlet side) Note this. Mark as needed.
Scheme 58
Note. Note and mark the position of the components before removal.
Note. Make sure that components are installed according to instructions from removing.
Remove the screws for the connecting rod cover. Lift off the cover. Ensure that the bearing cover comes with it.
The contact face between the cap and connecting rod is not machined. The fit takes place using a clean fracture surface.
Scheme 59
Note. Note and mark the position of the components before removal.
Note. Make sure that components are installed according to instructions from removing.
see 9995746
Install the tool in the connecting rod and press out the connecting rod/piston.
Hold your hand underneath so that the piston does not fall to the floor and make sure that the bearing half also comes out. Lay the piston with connecting rod so it can be reinstalled in the correct cylinder. Continue with cylinder 2, 3, 4, 5, 6 as above.
Scheme 60
Note. Note and mark the position of the components before removal.
Note. Make sure that components are installed according to instructions from removing.
First remove the intermediate part's M8 screws. Then continue with the M10 screws. Begin at the outer edges and work alternately towards the middle.
Carefully pry apart the intermediate part /engine block
Lift away the intermediate part. Make sure that the intermediate part's bearing halves also come out.
Scheme 61
Note. The crankshaft must not rotate.
Carefully lift the crankshaft straight up.
Scheme 62
Note. Note and mark the position of the components before removal.
Note. Make sure that components are installed according to instructions from removing.
Remove the remaining bearing halves.