Remove/install engine with transmission

AR01.10-P-2401OLD

Remove/install engine with transmission

08.01.2020

Engine

651 in model 205 with transmission 716

except code M005 (Vehicles with 4MATIC/all-wheel drive)

Engine

651 in model 205 with transmission 722 (except 722.96), 724

Engine

651 in model 205 with transmission 725

except code M005 (Vehicles with 4MATIC/all-wheel drive)

Modification notes

21.09.2017

Operation steps revised

Operation steps 1 to 51

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

1

Vacuum line separating point

4

Bracket

2

Rear right engine suspension lug

5

Electrical wiring harness

3

Coolant hose

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

6

Charge air pipe

11

Charge air cooler

7

Low-temperature circuit coolant line

12

Coolant hose

8

Bracket

13

Coolant hose

9

Screw

14

Refrigerant high-pressure line

10

Vent line

15

Refrigerant low-pressure line

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

16

Automatic transmission oil cooler

17

Low-temperature circuit coolant line

18

Coolant hose

19

Coolant hose

Shown: Engine 651 in model 205 with transmission 722.9 except code ME04 (mild hybrid drive)

20

Reinforcement

21

Ground cable

22

Fuel hoses

Shown: Engine 651 in model 205 with transmission 724.2 with code ME04 (mild hybrid drive)

23

High voltage electrical line

 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 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

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.

AS00.00-Z-0035-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system

AH00.00-Z-0300-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on engine oil and filter changes

AH18.00-P-0104-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A

Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases

AH01.10-P-0001-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

Notes on automatic transmission

Engine 651 in model 205 with transmission 722 (except 722.96), 724
Engine 651 in model 205 with transmission 725
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AH27.19-P-0001-01NKB

 

Remove/install

1

Secure vehicle to prevent it moving away.

2

Move transmission to neutral position and release the parking brake.

3

Deactivate easy entry and exit feature.

Engine 651 in model 205 with transmission 716
with code 275 (Driver's seat, electrically adjustable with memory function)
except code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 651 in model 205 with transmission 722 (except 722.96), 724
with code 275 (Driver's seat, electrically adjustable with memory function)

 Deactivation takes place over the "Vehicle settings" menu and submenu "Easy entry and exit feature" in multifunction display, see vehicle operator's manual.

4

Turn steering wheel to center position (front wheels in straight-ahead position) and fix in place using holding device.

AR46.20-P-0600-01LW

 Retainer device

*129589012100

5

Perform power disconnect of high-voltage on-board electrical system.

Engine 651 in model 205.012/212
with code ME04 (Mild hybrid drive)

AR54.10-P-1150LW

6

Discharge air conditioning system.

AR83.30-P-1760LW

7

Disconnect ground line from battery.

AR54.10-P-0003LW

8

Remove lower engine compartment linings.

AR61.20-P-1105LW

 Installation: Only install lower engine compartment lining after leak test.

9

Remove drain screw at oil pan, drain engine oil, and catch in suitable container.

 Installation: Replace sealing ring.

 Drain screw to oil pan

*BA01.45-P-1003-01S

10

Drain coolant at radiator.

AR20.00-P-1142LW

11

Drain coolant of low-temperature circuit.

AR09.41-P-6834LW

12

Remove upper engine cover.

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

13

Disconnect vacuum line of the vacuum pump at vacuum line connecting point (1).

14

Unhook vacuum line at bracket (arrow) and place to one side.

15

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130OLD

16

Remove charge air pipe (6) upstream of charge air cooler (11).

AR09.41-P-8623OLD

17

Remove bolt (9) and remove low-temperature circuit coolant line (7) from bracket (8).

 Bolt, low-temperature circuit coolant line to low-temperature circuit coolant line bracket

*BA09.41-P-1002-03C

18

Remove bleed line (10) at low-temperature circuit coolant expansion reservoir.

AR20.20-P-7441-01RQ

19

Remove coolant hose (12) from the thermostat housing.

AR20.20-P-7441-01RQ

20

Remove coolant hose (13).

AR20.20-P-7441-01RQ

21

Remove low-temperature circuit coolant line (7) from charge air cooler (11), place to one side and fix in place.

AR20.20-P-7441-01RQ

22

Remove coolant hose (18) at fitting.

AR20.20-P-7441-01RQ

23

Remove coolant hose (19).

AR20.20-P-7441-01RQ

24

Remove refrigerant high-pressure line (14) from refrigerant compressor, place to one side and seal openings using suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring and moisten sealing ring and thread with compressor oil.

 Refrigerant line to refrigerant compressor

*BA83.55-P-1003-01W

 Record plug

*129589009100

25

Remove refrigerant low-pressure line (15) and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring and moisten sealing ring and thread with compressor oil.

 Refrigerant line to refrigerant compressor

*BA83.55-P-1003-01W

 Record plug

*129589009100

26

Disconnect engine wiring harness for removal of engine and place to one side.

AR15.18-P-1000-03OLD

 Nut, positive line to engine compartment prefuse box

*BA54.15-P-1003-01K

27

Remove bracket (4) together with electrical wiring harness (5) from rear right engine lifting lug (2) and place to one side.

28

Remove coolant hose (3) from connection fitting for coolant return line at cylinder head and place to one side.

 Hose clamp pliers

*003589033700

29

Remove catalytic converter DPF unit.

AR49.10-P-5501LWB

30

Remove fan unit.

AR20.40-P-5050LWB

31

Fasten automatic transmission oil cooler (16) to engine free of tension.

Engine 651 in model 205 with transmission 722 (except 722.96), 724

32

Mount protective plate on cooler.



WF58.50-P-0110-01A

33

Disconnect steering coupling from steering shaft.

Engine 651 in model 205 with transmission 716
except code 700 (Technology Local Content China)
except code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 651 in model 205 with transmission 722 (except 722.96), 724
except code 700 (Technology Local Content China)
Engine 651 in model 205.0/2/3/4 with transmission 725
except code 700 (Technology Local Content China)
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR46.10-P-8000-01LW


Do not turn steering wheel with steering coupling removed.
Otherwise, the clock spring contact is damaged.

 Engine mount wrench set

*001589011600

34

Remove low-temperature circuit coolant line (17) from automatic transmission oil cooler (16).

Engine 651 with transmission 722 (except 722.96)

AR20.20-P-7441-01RQ

35

Disconnect ground line (21) from body.

36

Remove reinforcement (20).

 Bolt, front reinforcement/bracket to frame floor assembly

*BA61.10-P-1002-01L

37

Detach propeller shaft from output flange on transmission.

AR41.10-P-0050LW

 Mark installation position of propeller shaft in relation to output flange on transmission.

38

Detach center shifter console and shift rod from transmission.

Engine 651 in model 205 with transmission 716
except code M005 (Vehicles with 4MATIC/all-wheel drive)



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

AR26.60-P-0600-02LW

Long-life grease

*BR00.45-Z-1001-06A

39

Disconnect electrical connection for transmission neutral position sensor (B79/2) on the right side on the transmission.

Engine 651 in model 205 with transmission 716
except code M005 (Vehicles with 4MATIC/all-wheel drive)

40

Remove hydraulic hose at clutch slave cylinder and seal openings with suitable stop plugs.

Engine 651 in model 205 with transmission 716
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR25.20-P-0150LW

 Installation: Replace sealing ring.

 Record plug

*129589009100

41

Disconnect fuel hoses (22) at fuel lines and seal connections using suitable stop plugs.

 Pliers for click clamps

*171589003700

 Clamp

*000589403700

 Record plug

*129589009100

42

Remove rear engine mounts.

AR22.10-P-1160LWB

43

Install rear engine carrier.

AR22.10-P-4360LWB

44

Lower engine with transmission onto the rear engine support.


Engine 651 in model 205 with transmission 724.2
Carefully lower engine with transmission.
Otherwise the high voltage electrical lines (23) may be damaged.

45

Release and disconnect high voltage electrical lines (23) on high-voltage battery module and close off high-voltage plug with protective covers.

Engine 651 in model 205.012/212 with transmission 724.2

AR54.10-P-1400LW

 Set of protective covers

*001589039100

46

Remove high voltage electrical lines (23) through the transmission tunnel upwards in the engine compartment and lay on the right wheel arch.

Engine 651 in model 205 with transmission 724

47

Hook load tilter and boom crane into rear right engine lifting lug (2), left engine lifting lug and front center engine lifting lug, and raise the engine.



000 588 00 62 00 Load tilter

WS01.00-P-0102B


Do not subject the engine mounts to tension.
The engine mount can get damaged otherwise.

 Commercially available devices/tools
Boom crane

48

Remove screw/bolts of front engine mount to engine supports.

AR22.10-P-1260LWB

49

Lift out engine together with transmission.



000 588 00 62 00 Load tilter

WS01.00-P-0102B


Do not jam any component parts when lifting the engine with transmission in and out.
Otherwise, surrounding components may be damaged.

 Commercially available devices/tools
Boom crane

 Two helpers required.

50

Install in the reverse order.



Check

51

Check engine oil level and correct if necessary.



AP18.00-P-1811MP

52

Bleed clutch operating system.

Engine 651 in model 205 with transmission 716.7
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR25.20-P-0070LW

 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

53

Perform engine test run; while doing so, check engine and transmission for proper operation and leak tightness.

 Oil pan

Number

Designation

Engine 651

BA01.45-P-1003-01S

Drain screw to oil pan

Metal

Nm

30

Plastic

Nm

4

 Charge air cooler

Number

Designation

Engine 651 in model 205

BA09.41-P-1002-03C

Bolt, low-temperature circuit coolant line to low-temperature circuit coolant line bracket

Nm

8

 Fuse and relay box

Number

Designation

Model 205

BA54.15-P-1003-01K

Nut, positive line to engine compartment prefuse box

M6

Nm

8

M8

Nm

16

 Frame floor assembly

Number

Designation

Model 205

BA61.10-P-1002-01L

Bolt, front reinforcement/bracket to frame floor assembly

M10x20

Nm

-

M10x28

Nm

30

 Refrigerant compressor

Number

Designation

Engine 651 in model 117, 156, 166, 172, 176, 205, 212, 218, 221, 222, 246, 253

BA83.55-P-1003-01W

Refrigerant line to refrigerant compressor

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11