Remove/install engine with front axle carrier

AR01.10-P-2500GQA

Remove/install engine with front axle carrier

09.08.2019

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

1

Vacuum hose

8

Coolant hose

4

Coolant line

9

Steering coupling universal joint

5

Covers

Shown on engine 642 in model 166.024

12

Coolant hose

22

Centering plates

27

Transverse control arm

13

Fuel hoses

23

Diesel particulate filter

M13/5

Coolant circulation pump

19

Bolts

24

Rear engine crossmember

N37/7b1

NOx sensor downstream of diesel particulate filter

20

Bolts

25

Transfer case

Y129

AdBlue® metering valve

21

Front axle carrier

26

Clamp

 Danger

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

 Danger

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 contactwith 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

 Danger

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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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

 Warning

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

 Caution

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

 Caution

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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

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 (driver's seat, steering column and mirror))

4

Turn front wheels to straight-ahead position and fix steering wheel in place with holding device

 Installation: Remove holding device before connecting battery.

 Retainer device

*129589012100

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

 Installation: Only install upper engine cover after the leak test.

 Installation: Ensure correct seating of the 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

 Installation: Install underfloor paneling only after the leak test.

17

Disconnect engine wiring harness on the vehicle side

AR01.00-P-2410-02GQA

 Nut, circuit 30 in prefuse box

*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

 Check condition of coolant hoses, clamps and sealing ring; replace if necessary.

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

 Hose clamp pliers

*003589033700

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 (Additional warm water heating)

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

 Record plug

*129589009100

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.

 Screw must be fully removed, as it is guided in a groove.

 Bolt, steering coupling to steering shaft

*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 (BlueTEC diesel exhaust treatment (SCR))

AR14.40-P-2000GZB

 Installation: Replace seal.

 Installation: Install clamp before assembly of the transmission carrier.

30

Remove NOx sensor downstream of diesel particulate filter (N37/7b1)

 NOx sensor downstream of DPF

*BA14.40-P-1005-02A

31

Remove temperature sensor upstream of diesel particulate filter (23)

 Union nut, temperature sensor upstream of diesel particulate filter

*BA07.04-P-1006-01L

32

Open clamp (26) and disconnect exhaust system

 Bolt, clamp between exhaust input module and oxidation catalytic converter

*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 from lower control arms (27)

AR32.25-P-1017GQ

42

Disconnect fuel hoses (13) from fuel lines and seal exposed connections with suitable stop plugs

 Installation: Replace hose clamps.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

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

 When doing so ensure that mounting plates are evenly aligned.

44

Remove rear engine crossmember (24) with the rear engine mount

AR22.10-P-1180GQ

Topical note

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)

 Nut, exhaust rubber mount to exhaust system/centering plate/strut

*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

 Installation: Replace the screws/bolts (20).

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01I

48

Remove screws (19) at front axle carrier (21)

AR33.10-P-0100GQ

 Installation: Replace screws/bolts (19).

 Bolt, stiffening plate to longitudinal member

*BA33.10-P-1002-01I

49

Lower engine-transmission unit with front axle carrier (21)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


The engine must not touch the body panels or major assemblies, not crush any lines or effect any cable.
Otherwise damage will occur.

50

Attach load tilter and engine hoist to all engine lifting lugs



000 588 00 62 00 Load tilter

WS01.00-P-0102B

 Commercially available devices/tools
Engine crane

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

 Commercially available devices/tools
Engine crane

52

Remove engine mounts from engine carriers



000 588 00 62 00 Load tilter

WS01.00-P-0102B

AR22.10-P-1260GQA

 Commercially available devices/tools
Engine crane

53

Lift engine from front axle carrier (21)



000 588 00 62 00 Load tilter

WS01.00-P-0102B

 Commercially available devices/tools
Engine crane

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

AR27.00-P-0270EWN

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

 Warning

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

 Warning

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, BlueTec

Number

Designation

Engine 651 in model 166, 204, 207, 212, 218, 221, 222
with code U42 (BlueTEC 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-1001-01I

Bolt, front axle carrier to longitudinal member

M141.5

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-1002-01I

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