Remove/install engine with transmission - AR01.10-P-2401MNA
ENGINE 177 in MODEL 205
MODIFICATION NOTES
| 22.06.2016 | New basic date for fuel hose union nut on diagnostic socket/fuel line, inserted | Operation step 11 | BA07.03-P-1006-01H |
| 12.09.2016 | Check engine oil level; correct if necessary, added new | Operation step 48 |
| Risk of injury . Moving parts can pinch, crush or, in extreme cases even sever extremities. | No parts of the body or limbs should be within the operating area of mechanical components when moving components. | AS00.00-Z-0009-01A | |
| Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil | Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers. |
AS18.00-Z-0001-01A | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | AS00.00-Z-0017-01A | |
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| Remove/install | |||
| 1 | Shift transmission to neutral and release parking brake | ||
| 2 | Turn front wheels to straight-ahead position and secure steering wheel with holding device | The steering wheel must not be turned when detaching steering coupling. Otherwise the clock spring contact will be destroyed. |
Fig 8 |
| 3 | Secure vehicle on vehicle lift | AR00.60-P-0100CW | |
| 4 | Detach ground line from battery | AR54.10-P-0003LW | |
| 5 | Drain air conditioning system | AR83.30-P-1760LW | |
| 6 | Remove upper heat shield of the ATL | AR09.40-P-6026MNA | |
| 7 | Remove the ignition coil (23) | AR15.12-P-2003MNA | |
| 8 | Unclip electrical lines (24, 25) on heat shield (27) | ||
| 9 | Remove screw/bolts (26) and take out heat shield (27) | *BA09.40-P-1007-01ZA | |
| 10 | Relieve fuel pressure at diagnostic socket | AR07.03-P-1460-01MNA | |
| *BA07.03-P-1005-01H | |||
| Fig 9 | |||
| 11 | Detach fuel feed hose (1) at diagnostic socket of low-pressure line and close off openings with suitable stop plugs | *BA07.03-P-1006-01H | |
| Fig 10 | |||
| 12 | Drain off coolant of engine cooling system | AR20.00-P-1142LW | |
| 13 | Drain coolant from low-temperature circuit | AR09.41-P-6834MNA | |
| 14 | Detach coolant hose (15) from the coolant line | Fig 11 | |
| 15 | Release and disconnect electrical connection at fan unit on upper left | ||
| 16 | Remove front module carrier | AR62.30-P-1570LW | |
| 17 | Detach coolant line at upper fan unit | ||
| 18 | Remove the vent line (16) | AR20.20-P-7441-01RQ | |
| 19 | Detach oil cooler for A/T at fan unit and place to one side with attached oil lines | AR27.55-P-1000LW | |
| 20 | Detach upper coolant hose (13) at radiator | AR20.20-P-7441-01RQ | |
| 21 | Detach coolant line at lower fan unit | ||
| 22 | Detach lower coolant hose (12) at radiator | AR20.20-P-7441-01RQ | |
| 23 | Detach both coolant hoses at radiator for low-temperature water circuit | AR20.20-P-7441-01RQ | |
| 24 | Detach both refrigerant lines at condenser and close off openings with suitable stop plugs | *BA83.30-P-1002-01Q | |
| Fig 10 | |||
| 25 | Unlock and disconnect the electrical connection at the condenser pressure sensor | ||
| 26 | Remove radiator package completely upwards | AR20.20-P-3865MNA | |
| 27 | Detach vacuum line (17) at firewall | ||
| 28 | Detach vacuum hoses (3) at purge valves | ||
| 29 | Remove refrigerant line (4) at connecting point (5) and seal openings using suitable stop plugs | *BA83.30-P-1004-01Q | |
| Fig 10 | |||
| 30 | Detach coolant hoses at connection fitting (10, 11) | AR20.20-P-7441-01RQ | |
| 31 | Detach coolant hose (22) at coolant pump | AR20.20-P-7441-01RQ | |
| 32 | Detach coolant hose (14) at right charge air cooler | Fig 11 | |
| 33 | Detach coolant hose (6) at firewall | Fig 11 | |
| 34 | Disconnect engine wiring harness to remove engine and fasten outside the working area | AR01.00-P-2410-02MNA | |
| *BA27.40-P-1013-01A | |||
| *BA27.40-P-1014-01A | |||
| 35 | Unclip electrical connections (8) and place to one side | ||
| 36 | Detach center exhaust system from left and right CAT | AR49.10-P-7283MNA | |
| 37 | Detach holder for center exhaust system from transmission | AR49.10-P-7283MNA | |
| 38 | Remove steering coupling | AR46.10-P-8000LW | |
| 39 | Detach drive shaft with front flexible coupling from transmission | AR41.10-P-0050LW | |
| 40 | Remove rear engine mount and lower transmission on rear engine support | AR22.10-P-1160MNA | |
| 41 | Mount engine suspension lug (01) on cylinder head | ||
| *BA00.10-P-1003-04A | |||
| Fig 7 | |||
| 42 | Mount load tilter and boom crane on engine and raise engine somewhat | Only raise engine sufficiently that the engine mounts are not under tension. Otherwise damage can occur to the front engine mount. Load tilter Engine crane |
|
| 43 | Remove screw/bolts of front engine mount on engine supports and front axle carrier | AR22.10-P-4330MNA | |
| 44 | Raise engine further | Ensure during lifting that no lines and assembly parts lie on the bulkhead. Otherwise damage can occur to lines and assembly parts. |
|
| 45 | Take out front engine mount to the rear | ||
| 46 | Move engine with transmission to the front | Lift out and lift in engine carefully for a tilt of a maximum of 30°. Otherwise damage can occur to the lines and assembly parts through getting caught in moving parts and impacts can occur otherwise. |
|
| 47 | Install in the reverse order | ||
| Check | |||
| 48 | Check engine oil level; correct if necessary | ||
| AP18.00-P-1811MP | |||
| 49 | Read out fault memory using the diagnostic system and clear if necessary | ||
| AD00.00-P-2000-04B | |||
| Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | AS00.00-Z-0005-01A | |
| 50 | Carry out an engine test run, checking the engine for proper operation and leaktightness |
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1003-04A | M7 x 1 | Nm | 15 | 22 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA07.03-P-1005-01H | Dust protection cap to service connection | Nm | 1 |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 177 | |
|---|---|---|---|
| BA07.03-P-1006-01H | Union nut, fuel hose to diagnostic socket/fuel line | Nm | 24 |
TURBOCHARGER
| Number | Designation | Engine 177.980 | |
|---|---|---|---|
| BA09.40-P-1007-01ZA | Bolt, side heat shield to cylinder head cover | Nm | 9 |
HOUSING
| Number | Designation | Transmission 722.9 | |
|---|---|---|---|
| BA27.40-P-1013-01A | Bolt, ground line to transmission housing | Nm | 9 |
HOUSING
| Number | Designation | Transmission 722.9 | |
|---|---|---|---|
| BA27.40-P-1014-01A | Bolt, heat shield to transmission housing | Nm | 9 |
AIR CONDITIONING
| Number | Designation | Model 205 | |
|---|---|---|---|
| BA83.30-P-1002-01Q | Nut, line to condenser | Nm | 12 |
AIR CONDITIONING
| Number | Designation | Model 205 | |
|---|---|---|---|
| BA83.30-P-1004-01Q | Nut, refrigerant line to connecting point | Nm | 12 |