Remove/install engine with transmission · ar0110d2401we · Mercedes-Benz WIS

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

D54.10-1170-08

Shown on model 906 with CODE XM0 (Model refinement)

1	Positive line		X4/47	Circuit 30 battery
G1	On-board electrical system battery

D01.10-1178-09

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

D01.10-1179-06

 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

906 589 05 62 00

Support plate

651 589 08 40 00

Counterholder

651 589 02 40 00

Retaining lock

129 589 00 91 00

Record plug

651 589 00 40 00

Counterholder

Repair materials

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51 11

Referenced documents

ah0000n000101a Notes on self-locking nuts and bolts
ah0000p002001a Notes on threaded connections fastened using a tightening angle-based tightening process
ah4250p000101a Brake fluid notes
ah5400p000101a Information on preventing damage to electronic components due to electrostatic discharge
ah5410p000101a Notes on battery
ah5410p000101a
ap4600d4611a Check and correct power steering fluid level
ar0060d1000h Lift/jack up vehicle
ar0110d240002we Disconnect/connect hose and line connections
ar0110d240007we Install, disassemble removed engine on assembly stand
ar0110d240009we Attach, detach engine removal fixture
ar0110d2405we Remove/install engine cover
ar0110d240601we Perform run-in program after engine replacement
ar2660d662601b Detach/attach shift cables at transmission
ar2719d075001b Disconnect/connect electrical connectors on automatic transmission
ar2720d010001wf Detach/attach torque converter on driver
ar2720d010001wg Detach/attach torque converter on driver
ar2760d010002c Unhook/hook up selector lever Bowden cable on transmission
ar2760d010002we Unhook/hook up selector lever Bowden cable on transmission
ar4110d0050h Remove/install propeller shaft
ar5410d0003sd Disconnect/connect battery ground line
ar8355d5300we Remove/install refrigerant compressor
ar8830d1064sd Remove/install front module
ar8840d3000sd Remove/install engine hood
as0000z000501a 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.
as0000z001001a Risk of death caused by vehicle slipping or toppling off of the lifting platform.
as4250z000101a Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid
as4700z000101a 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.
ws0100n3014b 000 588 04 62 00 Removal fixture
ws0100n3028b 000 588 00 31 00 Assembly stand for cars
ws0100p0186b 000 588 08 31 00 Mounting fork adapter