Mercedes-Benz Truck 2000-05

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Verify that the rear engine lifting eyes are correct. The left lifting eye is marked with a star and code number 04, and the right lifting eye is marked with a star and code number 02.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Air baffle
     
    Engine cooling fan and clutch, then the fan shroud
     

  6.  


NOTE
The fan clutch is equipped with right-hand thread.

  1. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Air cleaner housing
     
    Resonance pipe and body
     
    Coolant hoses from the water pump and thermostat housing
     
    Radiator
     
    Coolant expansion tank
     
    Transmission dipstick tube from the cylinder head cover
     
    Brake booster vacuum hose from the rear of the intake manifold
     

  2.  
  3. Drain the power steering fluid from the pump.

    Hoses from the power steering pump, then plug the openings
     
    Vacuum hose at the purge control valve
     

  4.  
  5. Relieve the fuel system pressure.

    Fuel pipe
     
    Heater hose from the rear of the cylinder head
     
    Engine wiring harness
     

  6.  
  7. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Air conditioning compressor and position it aside, leaving the hoses attached
     
    Left inner fender liner
     
    Exhaust system from the manifolds
     
    Cable for the park lock interlock
     

  8.  
  9. Matchmark the torque converter-to-ring gear.

    Torque converter bolts
     
    Left and right Oxygen (O2S) sensors electrical connections
     
    Starter
     
    Engine-to-transmission mounting bolts. Leave the 2 upper bolts attached at this time.
     
    Motor mounts from the front suspension support
     
    Generator wiring harness
     
    Air conditioning compressor electrical connector
     
    Engine ground cable at the power steering pump
     

  10.  
  11. Attach the engine hoist to the lifting eyes, then raise the engine and support the transmission.
  12.  


NOTE
Be sure that the engine does not touch the body at the rear.

  1. Remove the 2 remaining engine-to-transmission mounting bolts.
  2.  
  3. Slowly pull the engine out to the front and lift it out.
  4.  

To install:

  1. Install or connect the following:

    Engine into the vehicle
     
    Engine to the transmission
     
    Upper 2 mounting bolts
     
    Engine ground cable to the power steering pump
     
    Motor mount bolts and tighten to 26 ft. lbs. (35 Nm)
     

  2.  
  3. Remove the engine hoist from the lifting eyes.

    Remaining engine-to-transmission mounting bolts and tighten to 30 ft. lbs. (40 Nm).
     
    Air conditioning compressor electrical connector
     
    Generator wiring harness
     
    Starter
     
    Left and right O2S sensors
     

  4.  
  5. Align the torque converter-to-ring gear matchmarks and tighten the bolts to 31 ft. lbs. (42 Nm).

    Starter and tighten bolts to 31 ft. lbs. (42 Nm).
     
    Cable for the park lock interlock
     
    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Air conditioning compressor
     
    Serpentine belt and remove the locking pin
     
    Engine wiring harness
     
    Coolant hoses to the water pump, cylinder head and thermostat housing
     
    Fuel pipe
     
    Vacuum hose to the purge control valve
     
    Power steering hoses to the pump and fill the reservoir
     
    Brake booster vacuum hose to the intake manifold
     
    Transmission dipstick tube to the cylinder head cover
     
    Coolant expansion tank
     
    Resonance pipe and body, then the air cleaner housing
     

  6.  
  7. Remove the radiator/condenser guard plate.

    Fan shroud and fan
     
    Engine undercover
     

  8.  
  9. Fill the engine with coolant and oil.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Read fault memory, encode the radio and normalize the power windows.
  14.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Verify that the rear engine lifting eyes are correct. The left lifting eye is marked with a star and code number 04, and the right lifting eye is marked with a star and code number 02.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The fan clutch is equipped with right-hand thread.



    Negative battery cable
     
    Engine undercover
     
    Engine cooling fan and clutch, then the fan shroud
     

  6.  
  7. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Air cleaner housing
     
    Resonance pipe and body
     
    Coolant hoses from the water pump and thermostat housing
     
    Coolant expansion tank
     
    Transmission dipstick tube from the cylinder head cover
     
    Brake booster vacuum hose from the rear of the intake manifold
     

  8.  
  9. Drain the power steering fluid from the pump.

    Hoses from the power steering pump, then plug the openings
     
    Vacuum hose at the purge control valve
     

  10.  
  11. Relieve the fuel system pressure.

    Fuel pipe
     
    Heater hose from the rear of the cylinder head
     
    Engine wiring harness
     

  12.  
  13. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Air conditioning compressor and position it aside, leaving the hoses attached
     
    Exhaust system from the manifolds
     
    Cable for the park lock interlock
     

  14.  
  15. Matchmark the torque converter-to-ring gear.

    Torque converter bolts
     
    Left and right Oxygen (O 2 S) sensors electrical connections
     
    Sarter
     
    Engine-to-transmission mounting bolts. Leave the 2 upper bolts attached at this time.
     
    Motor mounts from the front suspension support
     
    Generator wiring harness
     
    Air conditioning compressor electrical connector
     
    Engine ground cable at the power steering pump
     

  16.  
  17. Attach the engine hoist to the lifting eyes, then raise the engine and support the transmission.
    NOTE
    Be sure that the engine does not touch the body at the rear.

  18.  
  19. Remove the 2 remaining engine-to-transmission mounting bolts.
  20.  
  21. Slowly pull the engine out to the front and lift it out.
  22.  

To install:

  1. Install or connect the following:

    Engine into the vehicle
     
    Engine to the transmission
     
    Upper 2 mounting bolts
     
    Engine ground cable to the power steering pump
     
    Motor mount bolts and tighten to 26 ft. lbs. (35 Nm)
     

  2.  
  3. Remove the engine hoist from the lifting eyes.

    Remaining engine-to-transmission mounting bolts
     
    Air conditioning compressor electrical connector
     
    Generator wiring harness
     
    Starter
     
    Left and right O 2 S sensors
     

  4.  
  5. Align the torque converter-to-ring gear matchmarks and tighten the bolts to 31 ft. lbs. (42 Nm).

    Cable for the park lock interlock
     
    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Air conditioning compressor
     
    Serpentine belt and remove the locking pin
     
    Engine wiring harness
     
    Coolant hoses to the water pump, cylinder head and thermostat housing
     
    Fuel pipe
     
    Vacuum hose to the purge control valve
     
    Power steering hoses to the pump and fill the reservoir
     
    Brake booster vacuum hose to the intake manifold
     
    Transmission dipstick tube to the cylinder head cover
     
    Coolant expansion tank
     
    Resonance pipe and body, then the air cleaner housing
     

  6.  
  7. Remove the radiator/condenser guard plate.

    Fan shroud and fan
     
    Engine undercover
     

  8.  
  9. Fill the engine with coolant and oil.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Read fault memory, encode the radio and normalize the power windows.
  14.  



Click image to see an enlarged view

Fig. Exploded view of the engine mounting-M112 engines



Click image to see an enlarged view

Fig. Exploded view of the engine mounting-M113 engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Verify that the rear engine lifting eyes are correct. The left lifting eye is marked with a star and code number 04, and the right lifting eye is marked with a star and code number 02.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The fan clutch is equipped with right-hand thread.



    Negative battery cable
     
    Engine undercover
     
    Air baffle
     
    Engine cooling fan and clutch, then the fan shroud
     

  6.  
  7. Place a guard plate behind the radiator/condenser to protect it from damage during removal and installation.

    Air cleaner housing
     
    Resonance pipe and body
     
    Coolant hoses from the water pump and thermostat housing
     
    Radiator
     
    Coolant expansion tank
     
    Transmission dipstick tube from the cylinder head cover
     
    Brake booster vacuum hose from the rear of the intake manifold
     

  8.  
  9. Drain the power steering fluid from the pump.

    Hoses from the power steering pump, then plug the openings
     
    Vacuum hose at the purge control valve
     

  10.  
  11. Relieve the fuel system pressure.

    Fuel pipe
     
    Heater hose from the rear of the cylinder head
     
    Engine wiring harness
     

  12.  
  13. Lock the automatic belt tensioner by rotating the tensioner counterclockwise until a 5mm drift or pin fits through the tensioner.

    Serpentine belt
     
    Air conditioning compressor and position it aside, leaving the hoses attached
     
    Left inner fender liner
     
    Exhaust system from the manifolds
     
    Cable for the park lock interlock
     

  14.  
  15. Matchmark the torque converter-to-ring gear.

    Torque converter bolts
     
    Left and right Oxygen (O 2 S) sensors electrical connections
     
    Starter
     
    Engine-to-transmission mounting bolts. Leave the 2 upper bolts attached at this time.
     
    Motor mounts from the front suspension support
     
    Generator wiring harness
     
    Air conditioning compressor electrical connector
     
    Engine ground cable at the power steering pump
     

  16.  
  17. Attach the engine hoist to the lifting eyes, then raise the engine and support the transmission.
    NOTE
    Be sure that the engine does not touch the body at the rear.

  18.  
  19. Remove the 2 remaining engine-to-transmission mounting bolts.
  20.  
  21. Slowly pull the engine out to the front and lift it out.
  22.  

To install:

  1. Install or connect the following:

    Engine into the vehicle
     
    Engine to the transmission
     
    Upper 2 mounting bolts
     
    Engine ground cable to the power steering pump
     
    Motor mount bolts and tighten to 26 ft. lbs. (35 Nm)
     

  2.  
  3. Remove the engine hoist from the lifting eyes.

    Remaining engine-to-transmission mounting bolts and tighten to 30 ft. lbs. (40 Nm).
     
    Air conditioning compressor electrical connector
     
    Generator wiring harness
     
    Starter
     
    Left and right O 2 S sensors
     

  4.  
  5. Align the torque converter-to-ring gear matchmarks and tighten the bolts to 31 ft. lbs. (42 Nm).

    Starter and tighten bolts to 31 ft. lbs. (42 Nm).
     
    Cable for the park lock interlock
     
    Exhaust system to the manifolds and tighten the mounting nuts to 15 ft. lbs. (20 Nm)
     
    Air conditioning compressor
     
    Serpentine belt and remove the locking pin
     
    Engine wiring harness
     
    Coolant hoses to the water pump, cylinder head and thermostat housing
     
    Fuel pipe
     
    Vacuum hose to the purge control valve
     
    Power steering hoses to the pump and fill the reservoir
     
    Brake booster vacuum hose to the intake manifold
     
    Transmission dipstick tube to the cylinder head cover
     
    Coolant expansion tank
     
    Resonance pipe and body, then the air cleaner housing
     

  6.  
  7. Remove the radiator/condenser guard plate.

    Fan shroud and fan
     
    Engine undercover
     

  8.  
  9. Fill the engine with coolant and oil.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Read fault memory, encode the radio and normalize the power windows.
  14.  

 
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