Remove/Install Engine With Transmission - AR01.10-P-2401MNA
Engine 177 in model 205
MODIFICATION NOTES
| 21.06.2017 | Document reference added | Operation steps 25, 30 | BB00.40-P-0362-01A |
| 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 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. 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 | ||
| Notice | Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | ||
| Notice | Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notice | Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Notice | Notes on self-locking nuts and bolts | AH00.00-P-0001-01KOA | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | |||
| 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 against rolling | |||
| 2 | Shift transmission to neutral and release parking brake | |||
| 3 | Turn front wheels to straight-ahead position and fix steering wheel in place with holding device | Fig 4 | ||
| 4 | Disconnect ground cable at 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 electric lines (24, 25) at heat shield (27) | |||
| 9 | Unscrew screws (26) and remove 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 5 | ||||
| 11 | Remove fuel feed hose (1) at service connection of low-pressure line and seal openings with suitable stop plugs Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| *BA07.03-P-1006-01H | ||||
| Fig 3 | ||||
| 12 | Secure vehicle on vehicle lift | AR00.60-P-0100CW | ||
| 13 | Drain off coolant of engine cooling system | AR20.00-P-1142LW | ||
| 14 | Drain coolant from low-temperature circuit | AR09.41-P-6834MNA | ||
| 15 | Remove coolant hose (15) from coolant line | Fig 2 | ||
| 16 | Release and disconnect electrical connection at fan unit on upper left | |||
| 17 | Remove front module carrier | AR62.30-P-1570LW | ||
| 18 | Remove coolant line at upper fan unit | |||
| 19 | Remove the vent line (16) | AR20.20-P-7441-01RQ | ||
| 20 | Remove oil cooler for automatic transmission at fan unit and place to one side with connected oil lines | AR27.55-P-1000LW | ||
| 21 | Remove upper coolant hose (13) at cooler | AR20.20-P-7441-01RQ | ||
| 22 | Remove coolant line at lower fan unit | |||
| 23 | Remove lower coolant hose (12) at cooler | AR20.20-P-7441-01RQ | ||
| 24 | Remove coolant hoses (9, 22) at cooler for low-temperature water circuit | AR20.20-P-7441-01RQ | ||
| 25 | Remove both refrigerant lines at condenser and seal openings with suitable stop plugs | |||
| Compressor oils (specification 362.1) | BB00.40-P-0362-01A | |||
| *BA83.30-P-1002-01Q | ||||
| Fig 3 | ||||
| 26 | Unlock and disconnect the electrical connection at the condenser pressure sensor | |||
| 27 | Remove radiator package completely upwards | AR20.20-P-3865MNA | ||
| 28 | Remove vacuum line (17) on firewall | |||
| 29 | Detach vacuum hoses (3) at purge valves | |||
| 30 | Remove refrigerant line (4) at connecting point (5) and seal openings using suitable stop plugs | |||
| Compressor oils (specification 362.1) | BB00.40-P-0362-01A | |||
| *BA83.30-P-1004-01Q | ||||
| Fig 3 | ||||
| 31 | Remove coolant hoses at connection fittings (10, 11) | AR20.20-P-7441-01RQ | ||
| 32 | Remove coolant hose (22) at coolant pump | AR20.20-P-7441-01RQ | ||
| 33 | Remove coolant hose (14) at right charge air cooler | Fig 2 | ||
| 34 | Remove coolant hose (6) on firewall | Fig 2 | ||
| 35 | 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 | ||||
| 36 | Unclip electrical connectors (8) and place to one side | |||
| 37 | Remove center exhaust system from left and right catalytic converter | AR49.10-P-7283MNA | ||
| 38 | Remove steering coupling | Clock spring contact can otherwise be damaged. |
AR46.10-P-8000LW | |
| 39 | Remove propeller shaft with front flex disk from transmission | AR41.10-P-0050LW | ||
| 40 | Remove rear engine mount and lower transmission on rear engine carrier | AR22.10-P-1160MNA | ||
| 41 | Install lifting eye (01) at cylinder heads | *BA00.10-P-1003-04A | ||
| Fig 1 | ||||
| 42 | Install boom crane with load tilter at engine and slightly lift engine | |||
| 000 588 00 62 00 Load tilter | Front engine mounts can otherwise be damaged Boom crane |
WS01.00-P-0102B | ||
| 43 | Remove front engine mounts | AR22.10-P-4330MNA | ||
| 44 | Lift out engine with transmission toward front | |||
| 000 588 00 62 00 Load tilter | Lines and components can otherwise be damaged due to pinching and impacts. Boom crane |
WS01.00-P-0102B | ||
| 45 | Install in the reverse order | |||
| Check | ||||
| 46 | Check engine oil level; correct if necessary | |||
| AP18.00-P-1811MP | ||||
| 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 danger zone. |
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 | ||
| 47 | Perform an engine test run, check engine and transmission for proper operation and leaktightness while doing so | |||
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143
| Number | Designation | 8.8 | 10.9 | |
|---|---|---|---|---|
| BA00.10-P-1003-04A | M7X1 | 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 | |
|---|---|---|---|
| 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 | M6 | Nm | 12 |