Remove/install engine with transmission

AR01.10-D-2401WE

Remove/install engine with transmission

12.12.2018

Engine

651 in model 900

Engine

651.955/956/957 in model 906

Modification notes

10.12.2018

Workshop equipment 000 588 00 31 02 adaptation replaced by 000 588 08 31 00 mounting fork adapter.

Operation step 22

Shown on model 906 with CODE XM0 (Model refinement)

1

Positive line

X4/47

Circuit 30 battery

G1

On-board electrical system battery

Shown on model 906 with transmission 711

3

Propeller shaft

6

Diesel particulate filter/front muffler

9

Crossmember

4

Transmission

7

Pipe clamp

5

Screw

8

Exhaust pipe

10

Motor

11

Ground cable

12

Screw

13

Engine mount

14

Front axle carrier

15

Screw

16

Screw

17

Engine mount

 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

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

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

Brake fluid notes

AH42.50-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 

Remove/install

1

Disconnect ground line for on-board electrical system battery (G1)

AR54.10-D-0003SD

2

Remove positive line (1) from the battery circuit 30 (X4/47) and expose up to grommet (arrow A) in the battery box

3

Remove engine hood

AR88.40-D-3000SD

4

Remove front module

AR88.30-D-1064SD

5

Remove engine cover

AR01.10-D-2405WE

6

Jack up vehicle and secure

AR00.60-D-1000H

7

Disconnect hose and line connections

AR01.10-D-2400-02WE

 High pressure expansion hose to power steering pump

*BA46.30-N-1003-01A

 Bolt, vehicle speed sensor to transmission housing

*BA54.00-N-1003-01A

 Nut, circuit 30 to connection for battery box

*BA54.10-N-1001-01G

 Nut, circuit 30 to connection for connecting point

*BA54.10-N-1002-01G

 Bolt, refrigerant lines to refrigerant compressor

*BA83.55-N-1004-01L

 Steering gear oil

*BF46.00-N-1001-01A

 Record plug

*129589009100

8

Remove 2nd refrigerant compressor and hang to side with lines attached

Engine 651 in model 900
with code HK4 (Rear air conditioning, reinforced)
2nd refrigerant compressorEngine 651 in model 906.6
with code H08 (Roof-mounted air conditioning system, reinforced)
2nd refrigerant compressorEngine 651.955/956 in model 906.655/657
with code HK4 (Rear air conditioning, reinforced)
with code ZL3 (National version for Latin America)2nd refrigerant compressor

AR83.55-D-5300WE

9

Disconnect electrical connectors from transmission (4)

Engine 651.955/956/957 in model 906 with transmission 722.6

AR27.19-D-0750-01B

10.1

Remove shift cables from transmission (4)

Engine 651 in model 900 with transmission 711.680
Engine 651.955 in model 906 with transmission 711.680
Engine 651.956 in model 906 with transmission 711.680
Engine 651.957 in model 906 with transmission 711.680

AR26.60-D-6626-01B

Long-life grease

*BR00.45-Z-1001-06A

10.2

Unhook selector level cable from transmission (4)

Engine 651.955/956/957 in model 906 with transmission 722.6
Engine 651.955/956/957 in model 906 with transmission 722.9

Transmission 722.6 in model 906 with engine 651.955/956/957

AR27.60-D-0100-02C

Transmission 722.9 in model 906 with engine 651.955/956/957

AR27.60-D-0100-02WE

Long-life grease

*BR00.45-Z-1001-06A

11

Remove propeller shaft (3) at drive flange of transmission (4) and hang up to one side

AR41.10-D-0050H

12

Loosen pipe clamp (7) and push to the rear on the exhaust pipe (8)

 Installation: Clean sealing surfaces and replace gasket.

 Engine 651.955/956/957 in model 906
with code MS3 (Engine version EURO 3)Clamp, front muffler to main muffler

*BA49.10-N-1012-01I

 Engine 651.955/956/957 in model 906
except code MS3 (Engine version EURO 3)Clamp, diesel particulate filter to main muffler

*BA49.10-N-1004-01I

13

Insert suitable wooden block between the crossmember (9) and the transmission (4) (arrow B)

14

Remove screw/bolts (5) for rear engine mount

 Screw/bolt, rear engine mount to bracket

*BA22.10-N-1008-01S

15

Lower vehicle

16

Attach mounting plate to the engine (10)

AR01.10-D-2400-09WE

 Support plate

*906589056200

17

Remove screw/bolt (12) and place ground line (11) to one side

18

Remove screw/bolts (15, 16) for engine mount (13, 17)

 Nut/screw/bolt, front engine mount to front axle carrier

*BA22.10-N-1001-01S

19

Lift engine (10) with attached transmission (4) until the engine mounts (13, 17) no longer lie on the front axle carrier (14)


Carefully lift engine (10) with attached transmission (4).
Otherwise, adjacent component parts or component parts attached to the engine (10) may be damaged.

 Aid of 2 helpers required.

 Installation: Ensure correct seating of the engine mounts (13, 17) on the front axle carrier (14).

20

Lift engine (10) with attached transmission (4) toward the front out of the engine compartment with the aid of the removal fixture and an engine crane



000 588 04 62 00 Removal fixture

WS01.00-N-3014B


Carefully lift out engine (10) with attached transmission (4).
Otherwise, adjacent component parts or component parts attached to the engine (10) may be damaged.

 Aid of 2 helpers required.

 Installation: When installing a new engine (10): Before inserting the engine (10) in the engine compartment, change the corresponding detachable parts.

 Commercially available devices/tools
Engine crane

21

Remove torque converter from drive plate

Engine 651.955/956/957 in model 906 with transmission 722.686
Engine 651.955/956/957 in model 906 with transmission 722.9
For continued work for which the engine (10) must be attached to the assembly stand with the attached transmission (4).

Engine 651.955/956/957 in model 906 with transmission 722.686

AR27.20-D-0100-01WG

Engine 651.955/956/957 in model 906 with transmission 722.9

AR27.20-D-0100-01WF

 Transmission 722.9 in model 906 with engine 651.955/956/957Bolt, torque converter to drive plate

*BA27.20-N-1002-01F

 Transmission 722.686 in model 906 with engine 651.955/956/957Bolt, torque converter to drive plate

*BA27.20-N-1004-01C

 Counterholder

*651589084000

 Counterholder

*651589004000

 Retaining lock

*651589024000

22

Attach engine (10) to the assembly stand

When installing a new engine (10) or during continued work for which the engine (10) must be attached to the assembly stand.

AR01.10-D-2400-07WE



000 588 00 31 00 Assembly stand

WS01.00-N-3028B



000 588 08 31 00 Mounting fork adapter

WS01.00-P-0186B

 Bolt/nut, differential pressure sensor to bracket

*BA07.04-N-1010-01B

 Engine 651 in model 900
Engine 651.955/956/957 in model 906
except code MS3 (Engine version EURO 3)
Engine 651.955/956/957 in model 906
with code MS3 (Engine version EURO 3)Nut/bolt, bracket to front exhaust system

*BA49.10-N-1003-01I

 Screw/bolt, engine mount to front engine support

*BA22.10-N-1004-01S

 Engine 651 in model 900 with transmission 711.680
Engine 651.955/956 in model 906 with transmission 710.510
Engine 651.955/956/957 in model 906 with transmission 711.680Bolt, manual transmission to engine

*BA26.10-N-1001-01A

 Engine 651 in model 900 with transmission 711.680
Engine 651.955/956/957 in model 906 with transmission 711.680Bolt, exhaust bracket to transmission and exhaust

*BA26.40-N-1019-01A

 Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, filler pipe to cylinder head

*BA27.10-N-1001-04B

 Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, filler pipe to transmission housing

*BA27.10-N-1002-04B

 Engine 651.955/956/957 in model 906 with transmission 722.686
Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, transmission housing to engine

*BA27.10-N-1003-04B

 Engine 651.955/956/957 in model 906 with transmission 722.686
Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, bracket to transmission

*BA27.10-N-1011-04B

 Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, oil line to transmission housing

*BA27.55-N-1002-01I

 Engine 651.955/956/957 in model 906 with transmission 722.9Bolt, oil line double clamp to bracket

*BA27.55-N-1005-01I

 Engine 651 in model 900
Engine 651.955/956/957 in model 906
except code MS3 (Engine version EURO 3)Clamp securing diesel particulate filter to turbocharger

*BA49.10-N-1006-01I

 Engine 651.955/956/957 in model 906
with code MS3 (Engine version EURO 3)Clamp, front muffler to turbocharger

*BA49.10-N-1011-01I

 Record plug

*129589009100

23

Install in the reverse order

24

Check power steering oil level and correct if necessary



AP46.00-D-4611A

 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

25.1

Carry out an engine test run

For re-installation of the removed engine (10).

25.2

Perform run-in program after engine replacement

For installation of a new engine (10) or exchange of the engine (10).

AR01.10-D-2406-01WE


It is mandatory to perform the run-in program.
Damage can occur to the engine (10) otherwise.

26

Check engine (10) and check all line connection for leaktightness

 Sensors, transmitters

Number

Designation

Engine 651 in model 900
Engine 651 in model 906

BA07.04-N-1010-01B

Bolt/nut, differential pressure sensor to bracket

Nm

9

 Engine mounts, engine supports

Number

Designation

Engine 651 in model 900, 906

BA22.10-N-1001-01S

Nut/screw/bolt, front engine mount to front axle carrier

Nm

58

 Engine mounts, engine supports

Number

Designation

Engine 651 in model 900, 906

BA22.10-N-1004-01S

Screw/bolt, engine mount to front engine support

Nm

58

 Engine mounts, engine supports

Number

Designation

Engine 651 in model 900, 906

BA22.10-N-1008-01S

Screw/bolt, rear engine mount to bracket

Nm

40

 Manual transmission complete

Number

Designation

Transmission 710.510

Transmission 711.680

BA26.10-N-1001-01A

Bolt, manual transmission to engine

Nm

38

38

 Transmission housing

Number

Designation

Transmission 711.680

BA26.40-N-1019-01A

Bolt, exhaust bracket to transmission and exhaust

Nm

23

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1001-04B

Bolt, filler pipe to cylinder head

Nm

8

 Complete automatic transmission

Number

Designation

Transmission 722.9

BA27.10-N-1002-04B

Bolt, filler pipe to transmission housing

Nm

8

 Complete automatic transmission

Number

Designation

Transmission 722.686

Transmission 722.9

BA27.10-N-1003-04B

Bolt, transmission housing to engine

Nm

38

38

 Complete automatic transmission

Number

Designation

Transmission 722.686

Transmission 722.9

BA27.10-N-1011-04B

Bolt, bracket to transmission

Nm

23

23

 Torque converter

Number

Designation

Transmission 722.9

BA27.20-N-1002-01F

Bolt, torque converter to drive plate

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

 Torque converter

Number

Designation

Model 906 with transmission 722.683/684/685/686

BA27.20-N-1004-01C

Bolt, torque converter to drive plate

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-N-1002-01I

Bolt, oil line to transmission housing

Banjo bolt

Stage 1

Nm

5

Stage 2

°

90

Hexalobular bolt

Nm

12

 Transmission oil cooling

Number

Designation

Transmission 722.9

BA27.55-N-1005-01I

Bolt, oil line double clamp to bracket

Nm

8

 Power steering pump

Number

Designation

Model 900 with engine 651

Model 906 with engine 651

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

38

38

VDA pump

Nm

–

–

VT pump

Nm

–

–

 Exhaust system

Number

Designation

Engine 651 in model 900

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

23

 Exhaust system

Number

Designation

Engine 651 in model 906
with code MS3 (Engine version EURO 3)

BA49.10-N-1003-01I

Nut/bolt, bracket to front exhaust system

Nm

23

 Exhaust system

Number

Designation

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1004-01I

Clamp, diesel particulate filter to main muffler

Nm

35

 Exhaust system

Number

Designation

Engine 651 in model 900

Engine 651 in model 906
except code MS3 (Engine version EURO 3)

BA49.10-N-1006-01I

Clamp securing diesel particulate filter to turbocharger

Nm

15

15

 Exhaust system

Number

Designation

Engine 651 in model 906
with code MS3 (Engine version EURO 3)

BA49.10-N-1011-01I

Clamp, front muffler to turbocharger

Nm

15

 Exhaust system

Number

Designation

Engine 651 in model 906
with code MS3 (Engine version EURO 3)

BA49.10-N-1012-01I

Clamp, front muffler to main muffler

Nm

35

 Pulse generator

Number

Designation

Model 900 with engine 651

Model 906 with engine 651

BA54.00-N-1003-01A

Bolt, vehicle speed sensor to transmission housing

Nm

10

10

 Battery

Number

Designation

Model 906 with code MJ7 (ECO start/stop function)

Model 906 with code MJ8 (ECO start/stop function)

BA54.10-N-1001-01G

Nut, circuit 30 to connection for battery box

M8

Nm

16

16

 Battery

Number

Designation

Model 906
except code E30 (Battery master switch)
except code E36 (Disconnecting relais if auxiliary battery)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)

Model 900
with code E36 (Disconnecting relais if auxiliary battery)
Model 906
with code E36 (Disconnecting relais if auxiliary battery)
except code E30 (Battery master switch)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)

BA54.10-N-1001-01G

Nut, circuit 30 to connection for battery box

M8

Nm

16

16

 Battery

Number

Designation

Model 906 with code MJ7 (ECO start/stop function)

Model 906 with code MJ8 (ECO start/stop function)

BA54.10-N-1002-01G

Nut, circuit 30 to connection for connecting point

M8

Nm

16

16

 Battery

Number

Designation

Model 906
except code E30 (Battery master switch)
except code E36 (Disconnecting relais if auxiliary battery)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)

Model 900
with code E36 (Disconnecting relais if auxiliary battery)
Model 906
with code E36 (Disconnecting relais if auxiliary battery)
except code E30 (Battery master switch)
except code MJ7 (ECO start/stop function)
except code MJ8 (ECO start/stop function)

BA54.10-N-1002-01G

Nut, circuit 30 to connection for connecting point

M8

Nm

16

16

 Refrigerant compressor

Number

Designation

Model 900 with engine 651.955

Model 906 with engine 651 without code H08 or without code N63

BA83.55-N-1004-01L

Bolt, refrigerant lines to refrigerant compressor

Nm

22

22

 Refrigerant compressor

Number

Designation

Model 906 with engine 651 with code H08 or without code N63

BA83.55-N-1004-01L

Bolt, refrigerant lines to refrigerant compressor

Nm

22

 Steering

Number

Designation

Model 900

Model 906

BF46.00-N-1001-01A

Steering gear oil

Filling capacity

Liter

1,0

1,0

Sheet

BB00.40-P-0236-03A

BB00.40-P-0236-03A

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11