Remove/Install Engine With Front Axle Carrier - AR01.10-P-2500GQA
ENGINE 651 in MODEL 166.0
MODIFICATION NOTES
| 21.07.2017 | Operation steps revised. | Operation step 1 to operation step 59. |
Shown on engine 651 in model 166.004
Shown on engine 642 in model 166.024
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| 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 | |
| Risk of explosion
caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure |
Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized. |
AS07.16-Z-0001-01A | |
| Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. | Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. |
AS20.00-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 to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil | Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles. |
AS00.40-Z-0001-01A | |
| 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 | |
| Notes on coolant | AH20.00-N-2080-01A | ||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | ||
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Notes on active roll stabilization | Engine 651 in model 166.0 with code 468 (ACTIVE CURVE SYSTEM) Engine 651 in model 166.0 with code 468 (Active driving stability (stability)) |
AH32.34-P-0001-01A | |
| Notes on coolant level | AH20.00-P-1142-01CW | ||
| Notes on automatic transmission | AH27.19-P-0001-01NKB | ||
| Notes on AIRmatic | Engine 651 in model 166.0 with code 489 (AIRMATIC) | AH32.22-P-1000-02GZ | |
| Notes about Common-Rail components | AH07.16-P-0002-01TX | ||
| Notes on repair work on suspension components | AH00.00-P-0100-01A | ||
| Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases | AH01.10-P-0001-01A | ||
| Remove/install | |||
| 1 | Secure vehicle on vehicle lift | AR00.60-P-0100GZ | |
| 2 |
Relieve all pressure in front suspension struts with diagnostic system | Engine 651 in model 166.0 with code 489 (AIRMATIC) | AD00.00-P-2000-04A |
| 3 | Deactivate easy entry/exit feature | Engine 651 in model 166.0 with code 275 (Memory package) | |
| 4 | Turn front wheels to straight-ahead position and fix steering wheel in place with holding device | Figure | |
| 5 | Move DIRECT SELECT gear selector switch to position N and release parking brake | ||
| 6 | Disconnect ground line from battery | AR54.10-P-0003GZ | |
| 7 | Remove upper engine cover | ||
| 8 | Remove engine suction fan ducts in front of air filter | ||
| 9 | Remove charge air hose upstream of charge air cooler | AR09.41-P-8619CD | |
| 10 | Remove charge air hose downstream of charge air cooler | AR09.41-P-8619CD | |
| 11 | Disconnect vacuum hose (1) at connecting point next to the LH cover (5) | ||
| 12 | Remove covers (5) | ||
| 13 | Remove right partition wall section | ||
| 14 |
Remove wheel and tire assemblies of front axle | AP40.10-P-4050EW | |
| 15 | Remove left and right front section of fender liners in front fenders | AR88.10-P-1310GQ | |
| 16 | Remove underfloor paneling | AR61.30-P-1001GQ | |
| 17 | Disconnect engine wiring harness on the vehicle side | AR01.00-P-2410-02GQA | |
| *BA54.10-P-1002-01C | |||
| 18 | Drain coolant at radiator | AR20.00-P-1142GQ | |
| 19 | Remove lower and upper coolant hose at radiator | AR20.20-P-7441-01RQ | |
| 20 | Remove coolant hose from coolant pump | ||
| 21 | Remove coolant line (4) at connection fitting of coolant expansion reservoir and at radiator | ||
| 22 | Remove coolant line (4) at thermostat bracket | ||
| 23 | Remove coolant hose (8) from heater cooler at partition | Figure | |
| 24 | Disconnect coolant hose (12) at coolant circulation pump (M13/5) and unclip at longitudinal member | Engine 651 in model 166.0 with code 228 (Auxiliary heater) | |
| 25 | Release and disconnect electrical connector at fan unit | AR20.40-P-5050GQ | |
| 26 | Remove oil lines of automatic transmission at cooler connections on right side of oil cooler and seal exposed connections with suitable stop plugs | AR27.55-P-0600GQ | |
| Figure | |||
| 27 | Disconnect steering coupling universal joint (9) on steering shaft above | Do not turn steering wheel with steering coupling removed. Otherwise the clock spring contact will be destroyed. |
*BA46.10-P-1001-01J |
| 28 | Remove refrigerant compressor (A9) with connected lines at engine and secure at side | AR83.55-P-5300GQ | |
| 29 | Open clamp and remove AdBlue® metering valve (Y129) | Engine 651 in model 166.0 with code U42 (Blue TEC diesel exhaust treatment (SCR)) |
AR14.40-P-2000GZB |
| 30 | Remove NOx sensor downstream of diesel particulate filter (N37/7b1) | *BA14.40-P-1005-02A | |
| 31 | Remove temperature sensor upstream of diesel particulate filter (23) | *BA07.04-P-1006-01L | |
| 32 | Open clamp (26) and disconnect exhaust system | *BA49.10-P-1007-01AK | |
| 33 | Remove rear propeller shaft at transfer case (25) and secure against falling down | AR41.10-P-0050GQ | |
| 34 | Remove heat shield at transfer case (25) | Engine 651 in model 166.0 (except 166.006) with transmission 722.9 with code 430 (On & off-road package) | AR28.10-P-0100GQ |
| 35 | Release and disconnect electrical connectors at absolute sensor, actuator motor and switchover valve at transfer case (25) | Engine 651 in model 166.0 (except 166.006) with transmission 722.9 with code 430 (On & off-road package) | AR28.10-P-0100GQ |
| 36 | Unclip brake hoses at steering knuckles | ||
| 37 | Disconnect wiring harness and electrical connection at right front brake wear sensor | ||
| 38 | Remove rpm sensors at steering knuckles, unclip from bracket and place to one side | AR42.30-P-0712GZ | |
| 39 | Remove brake caliper supports, secure with brake calipers as well as connected lines to reinforcements in wheel well and secure against falling down | AR42.10-P-0070GZ | |
| 40 | Remove upper transverse control arms at steering knuckles | AR33.25-P-0400GZ | |
| 41 | Remove suspension struts at lower transverse control arms (27) | AR32.25-P-1017GQ | |
| 42 | Disconnect fuel hoses (13) from fuel lines and seal exposed connections with suitable stop plugs | Fig 2 | |
| Figure | |||
| 43 |
Support front axle carrier (21) with lifting platform as well as major assembly mount and secure entire engine-transmission unit with a suitable tool against slipping and falling down 000 588 03 62 00 Lifting platform | WS01.00-P-0091A | |
| 44 | Remove rear engine crossmember (24) with the rear engine mount | AR22.10-P-1180GQ | |
| Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | ||
| 45 | Remove diesel particulate filter (23) | AR49.10-P-5501GQ | |
| 46 | Unscrew nut from elastomer bearing of diesel particulate filter (23) from left centering plate (22) | *BA49.10-P-1006-01AK | |
| 47 | Remove screws (20) of centering plates (22) at front axle carrier (21) from longitudinal members | AR33.10-P-0100GQ | |
| *BA33.10-P-1001-011 | |||
| 48 | Remove screws (19) at front axle carrier (21) | AR33.10-P-0100GQ | |
| *BA33.10-P-1002-011 | |||
| 49 |
Lower engine transmission unit with front axle carrier (21) 000 588 03 62 00 Lifting platform |
The engine must not touch the body panels or major assemblies, not crush any lines or effect any cable. Otherwise damage will occur. |
WS01.00-P-0091A |
| 50 |
Attach load tilter and engine hoist to all engine lifting lugs 000 588 00 62 00 Load tilter |
WS01.00-P-0102B | |
| 51 |
Remove transmission with torque converter 000 588 00 62 00 Load tilter | WS01.00-P-0102B | |
| Engine 651 in model 166.0 with transmission 725.0 | AR27.10-P-0500GN | ||
| Engine 651 in model 166.0 with transmission 722.9 |
AR27.10-P-0500GQ | ||
| 52 |
Remove engine mounts from engine carriers 000 588 00 62 00 Load tilter |
WS01.00-P-0102B | |
| AR22.10-P-1260GQA | |||
| 53 |
Lift engine from front axle carrier (21) 000 588 00 62 00 Load tilter | WS01.00-P-0102B | |
| 54 | Install in the reverse order | ||
| Concluding tasks | |||
| 55 | Fill in coolant | AR20.00-P-1142GQ | |
| 56 | Check engine cooling system for leaktightness | AR20.00-P-1010GQ | |
| 57 | Check transmission oil level and correct if necessary | Engine 651 in model 166.0 with transmission 725.0 as of model year 2015 | AR27.00-P-0270EWN |
| Engine 651 in model 166.0 with transmission 725.0 up to model year 2015 | AR27.00-P-0270EWM | ||
| Engine 651 in model 166.0 with transmission 722.9 (except 722.96/97) | AR27.00-P-0270W | ||
| 58 | Perform wheel alignment check | AR40.20-P-0200GQ | |
| Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-Z-0001-01A | |
| 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 | |
| 59 | Perform an engine test run, check engine and transmission for proper operation and leaktightness while doing so |
TRANSMITTERS, PICK-UPS, SENSORS
| Number | Designation | Engine 651 | |
|---|---|---|---|
| BA07.04-P-1006-01L | Union nut, temperature sensor upstream of diesel particulate filter | Nm | 45 |
EXHAUST AFTERTREATMENT, BLUE TEC
| Number | Designation | Engine 651 in model 166, 204, 207, 212, 218, 221, 222 with code U42 (Blue TEC diesel exhaust treatment (SCR)) |
Engine 651 in model 166 with code U77 (Diesel Emission control BLUETEC (SCR)) |
|
|---|---|---|---|---|
| BA14.40-P-1005-02A | NOx sensor downstream of DPF | Nm | 60 | 60 |
FRONT AXLE CARRIER
| Number | Designation | Model 166 | |||
|---|---|---|---|---|---|
| BA33.10-P-1001-011 | Bolt, front axle carrier to longitudinal member | M14x1.5 | Stage 1 | Nm | 100 |
| Stage 2 | ∠° | 120 | |||
| Stage 3 | ∠° | -180 | |||
| Stage 4 | Nm | 100 | |||
| Stage 5 | ∠° | 90 | |||
FRONT AXLE CARRIER
| Number | Designation | Model 166 | ||
|---|---|---|---|---|
| BA33.10-P-1002-011 | Bolt, stiffening plate to longitudinal member | M10 | Nm | 60 |
STEERING SHAFT
| Number | Designation | Model 166 | |
|---|---|---|---|
| BA46.10-P-1001-01J | Bolt, steering coupling to steering shaft | Nm | 42 |
EXHAUST SYSTEM
| Number | Designation | Engine 651 in model 166 | |
|---|---|---|---|
| BA49.10-P-1006-01AK | Nut, exhaust rubber mount to exhaust system/centering plate/strut | Nm | 20 |
EXHAUST SYSTEM
| Number | Designation | Engine 651 in model 166 | |
|---|---|---|---|
| BA49.10-P-1007-01AK | Bolt, clamp between exhaust input module and oxidation catalytic converter | Nm | 17 |
BATTERY
| Number | Designation | Model 166 | |
|---|---|---|---|
| BA54.10-P-1002-01C | Nut, circuit 30 in prefuse box | Nm | 15 |