Removal and installation the engine (Mercedes-Benz Vario 814)

Removal

1. Disconnect the negative cable from the battery.

2. Remove the service cover.

3. Remove the split beam.

4. Remove the front engine brackets (on all-wheel drive vehicles).

5. Remove the rear engine cross member (on all-wheel drive vehicles).

6. Remove the engine and gearbox sump protective covers (on cars 904.904/908 up to number 049131).

7. Remove the radiator.

8. Remove the inlet pipe 5 and the compressed air supply pipe 2 (figure 3.1).

Figure 3.1. Removing and installing the engine: 1 - Engine; 2 - Compressed air supply pipe; 3, 8, 11, 15, 20, 26, 29, 35 - Bolts; 4, 19 - Gaskets; 5 - Inlet pipe; 6 - Compressed air supply tube; 7, 12, 16 - Clamps; 9 - Engine support; 10 - Generator Wiring Connectors; 13 - "Ground" connection wires; 14 - Engine brake pressure line; 17 - Exhaust pipe; 18 - Gear shift lever; 22, 23, 23, 30 - Wiring connectors; 25 - Cardan shaft; 27 - Nut; 28 - Clutch slave cylinder; 31 - Fuel line of the manual fuel pump; 32 - Fuel line to fuel filter; 33 - Vacuum tube; 34 - Power steering pump; 36 - Cross-cut plate; 37, 38 - Cooling system pipes; 39 - Lift; A6 - PLD control unit; G2 - Generator; M1 - Starter.

9. Remove the compressed air supply tube 6.

10. Disconnect pipe 38 from the cooling system pump.

11. Disconnect pipe 37 from the timing belt cover.

12. Disconnect the ground wires 13 from the timing belt cover.

13. Disconnect pipe 14 from the engine brake cylinder (cars with engine brake).

14. Disconnect fuel line 31 from the hand priming pump and fuel line 32 from the fuel filter.

15. Disconnect the discharge line from the constant throttle (constant throttle engines).

16. Disconnect vacuum tube 33 from the vacuum pump (engines with vacuum pump).

17. Disconnect the pipes from the compressor.

18. Remove the power steering pump 34 from the vacuum pump or compressor without disconnecting the oil lines and secure it to the side.

19. Disconnect connector 23 from the reversing light switch.

[Information copied from the website: www.mercedesman.ru]

20. Disconnect the wiring connector 22 from the neutral position sensor.

21. Disconnect speed sensor 24 from the speedometer. Replace the sealing ring.

22. Disconnect the propeller shaft 25 from the gearbox.

23. Remove the exhaust pipe 17.

24. Remove gear shift lever 18.

25. Unscrew bolts 15 and disconnect the gearbox mounting bracket.

26. Remove engine 1 using lift 39.

27. Disconnect the gearbox from engine 1.