Remove, install engine with transmission

AR01.10-P-2401FF

Remove, install engine with transmission

11.5.06

 

Remove/install

1

Remove engine hood

AR88.40-P-3000FF

2

Remove paneling on center piece in front of the windshield

AR88.00-P-2792FF

3

Remove battery tray

AR54.00-P-0002FF

4.1

Pry ball heads for shift cables (2) off transmission (1) and loosen shift cables (2) out of the brackets on transmission (1)

Only with transmission 717.470/471

5

Remove lead (3)

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

6

Spread clamp (4), pull fuel line (5) off fuel distributor (6) and seal openings using suitable plugs

 Catch fuel running out with suitable vessel.

7

Remove vacuum line for brake booster (7)

 Do not pull vacuum line of brake booster (7) out of brake booster.

Vehicles with code (LHD) Left-hand drive vehicle

AR43.10-P-0355FF

Vehicles with code (RHS) Right-hand drive vehicle

AR43.10-P-0355FI

 Danger!

Risk of injury to skin and eyes caused by 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

8

Turn cooling system cap on radiator counterclockwise through half a revolution, release overpressure, then unscrew cap on cooling system expansion reservoir.

9.1

Detach electrical wiring harness on shift actuator

Only for transmission 717.474

AR26.60-P-0040-01FF

10.1

Remove poly-V-belt

Only for vehicles with code (I01) Air conditioning Plus or code (I77) Manual AC

AR13.22-P-1202FF

10.2

Detach lower engine compartment paneling

Only on vehicles without code (I01) Air conditioning Plus or without code (I77) Manual AC

AR61.20-P-1105FF

11.1

Remove refrigerant compressor

Only for vehicles with code (I01) Air conditioning Plus or code (I77) Manual AC

AR83.55-P-5300-04FF



*BA83.55-P-1001-01L



*BA83.55-P-1002-01L

12

Lower vehicle with lifting platform

13

Detach engine wiring harness from engine and place aside

AR01.00-P-2420-01FF



*BA15.30-P-1002-01I



*BA15.40-P-1001-01J

14

Drain transmission oil

AR26.00-P-0200FF

15.1

Detach slave cylinder at transmission

Only with transmission 717.470/471

AR25.20-P-0150-01FF



*BA25.20-P-1002-01D

16

Remove front drive shafts

AR33.30-P-0620FF

17

Lower vehicle with lifting platform

18

Remove exhaust manifold

Engine 134.9 in model 454.0 with code (RHD) Right-hand drive vehicle

AR14.10-P-3915FI

Engine 134.9 in model 454.0 with code (LHD) Left-hand drive vehicle

AR14.10-P-3915FG

Engine 135.9 in model 454.0 with code (LHD) Left-hand drive vehicle

AR14.10-P-3915FF

19

Remove lower transmission bearing

AR26.10-P-0031FF

20

Drain coolant

AR20.00-P-1142FF

21

Lower vehicle with lifting platform

22

Remove coolant hoses (11, 12, 13) on engine

 Collect the escaping coolant in a suitable container.

23

Install engine bridge

AR01.10-P-2400-05FF



*BA22.10-P-1003-01Q



*BA22.10-P-1004-01Q



*BA22.10-P-1005-01Q



*454589006100



*454589040900

24

Unscrew bolt (9) and unscrew nuts (10)

 Install new self-locking bolt (9) and nuts (10).



*BA26.00-P-1002-01D



*BA26.00-P-1003-01D

25

Lower engine and transmission (1) using engine crossmember and position horizontally

 When lowering the transmission (1) loosen the transmission bearing (8) from the transmission (1) using a suitable screwdriver.



*454589006100

26

Remove engine with removal fixture

 The base jacks from companies Mazzola and AS Hydraulic can be used according to choice.

AR01.10-P-2400-01FF



*454589006100



*454589006200

 Base jack Co. Mazzola

*WH58.30-Z-1011-07A

 Base jack from co. AS Hydraulic

*WH58.30-Z-1011-07A

27

Install in the reverse order

Number

Designation

Engine
134.9

Engine
135.9

BA15.30-P-1002-01I

Nut, terminal 30 to starter

Nm

11

11

Number

Designation

Engines 134.910/911 135.930/950

BA15.40-P-1001-01J

Nut, circuit B+ to alternator

Nm

14

Number

Designation

Engine
134.9

Engine
135.9

BA22.10-P-1003-01Q

Nut, engine bracket to engine mount

Nm

48

48

BA22.10-P-1004-01Q

Nut, engine bracket to timing case cover

Nm

48

48

BA22.10-P-1005-01Q

Bolt, engine bracket to timing case cover

Nm

48

48

Number

Designation

Model
454.0

BA25.20-P-1002-01D

Torx bolt, clutch slave cylinder to transmission

Nm

18

Number

Designation

Trans-mission
717 except 717.478

BA26.00-P-1002-01D

Bolt, transmission mount to transmission

Nm

41

BA26.00-P-1003-01D

Nut, transmission bearing to transmission

Nm

41

Number

Designation

Engine
134.910

Engine
134.911

BA83.55-P-1001-01L

Torx bolt, refrigerant compressor to bracket

Nm

20

20

BA83.55-P-1002-01L

Torx bolt, refrigerant compressor on crankcase

Nm

20

20

Number

Designation

Engine
135.930

Engine
135.950

BA83.55-P-1001-01L

Torx bolt, refrigerant compressor to bracket

Nm

20

20

BA83.55-P-1002-01L

Torx bolt, refrigerant compressor to crankcase

Nm

20

20

Number

Designation

WH58.30-Z-1011-07A

Base jack