Remove/install engine

AR01.10-P-2400VB

Remove/install engine

20.3.12

25.6.10

Value modified: self-locking nut, flexible coupling to transmission and front propeller shaft, M10

*BA41.10-P-1001-01A

Value modified: self-locking nut, flexible coupling to transmission and front propeller shaft, M12

*BA41.10-P-1001-01A

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only pour liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect ground line from battery

AR54.10-P-0003V



Notes on battery

AH54.10-P-0001-01A

2

Remove air filter housing

AR09.10-P-1150VA

3

Remove fan shroud

AR20.40-P-6800VA

4

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

5

Remove poly-V belt (1)

AR13.22-P-1202VA

6

Suction off oil out of power steering expansion reservoir (2)



*210589007100

7

Detach return line (3) from power steering expansion reservoir (2)



*BA46.30-P-1012-01D

8

Detach pressure line (4) for power steering from power steering pump by unscrewing union nut (5)

 Installation: Replace sealing ring.



*BA46.30-P-1002-01D

9

Detach lower engine compartment paneling

AR61.20-P-1105V

10

Drain coolant at radiator

AR20.00-P-1142VA

11

Drain engine oil



Engine oil and filter change

AP18.00-P-0101VA

 Installation: Replace sealing ring.



*BA01.45-P-1001-01M



*BF18.00-P-1001-01M

12

Detach pressure line (4) of power steering from oil pan by unscrewing screw/bolt (6)



*BA01.45-P-1004-01M

13

Remove coolant compressor (A9) from timing case cover and engine support by unscrewing screw/bolts (7)

 Disconnect refrigerant compressor connector (A9x1) and attach refrigerant compressor (A9) with connected pipe system, laterally at bottom of engine compartment.



*BA83.55-P-1001-01M

14

Remove propeller shaft from drive flange of transmission

AR41.10-P-0050-02V



*BA41.10-P-1001-01A

15

Detach center shifter console and shift rod on transmission

AR26.60-P-0600-02V

16

Remove rear engine mount

 After removing rear engine mount, lower the transmission jack and let the transmission rest on the engine crossmember.

AR22.10-P-1160VA

Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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

17

Disconnect hydraulic line (8) of clutch operation

 Seal the connections.



*BA25.20-P-1002-01B



*129589009100



Brake fluid notes

AH42.50-P-0001-01A

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

18

Detach exhaust system from the exhaust manifolds by unscrewing the screw/bolts (13)

 Installation: Clean connecting points of combustion and corrosion residues, replace bolts (13).



*BA49.10-P-1001-01N

19

Remove engine wiring harness to remove engine

AR01.00-P-2410-02VD

20

Remove vacuum line (14) of purge control valve (Y58/1) from vacuum line (15) of crankcase ventilation system.

21

Remove vacuum line of brake booster

AR43.10-P-0355VA

22

Remove coolant hose (18)

 Check condition of coolant hose (18). Replace it if necessary.

23

Detach coolant hose (19) from coolant pump and pull from bracket (20)

 Check condition of the coolant hose (19). Replace it if necessary.

24

Detach coolant hose (21) from connection at coolant hose (22)

 Check condition of coolant hose (21). Replace it if necessary.

25

Detach coolant hose (22) from partition wall by disengaging securing clamp

 Check condition of coolant hose (22). Replace it if necessary.

26

Reduce fuel pressure through service valve

AR07.03-P-1460-01VA



*BA07.03-P-1004-01B



*119589046300

27

Detach fuel line (23) from fuel distributor

 Collect feathering-out fuel and seal connections.



*BA07.03-P-1001-01B



*129589009100

28

Disconnect engine mount from front axle carrier; to do this unscrew bolts (24)



*BA22.10-P-1006-01O

29

Lift out engine

 When lifting out engine ensure that the steering coupling is not damaged, no cables and lines are damaged and the engine does not touch the partition wall.

 Slightly raise engine equally at front and back, pull slightly forward, then lower back and lift out.

Engine hoist

30

Install in the reverse order

31

Bleed clutch operating system

AR25.20-P-0070V

32

Inspect transmission oil level

 Correct oil level = 10 mm below the bottom edge of the filler opening. Carry out measurement e. g. with a slanted hexagon socket wrench.



*BF26.10-P-1001-01C



*BA26.40-P-1003-01C



*BA26.40-P-1004-01C

33

Fill power steering pump and bleed

AR46.30-P-0010V

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

34

Carry out engine test run

 Check fuel line screw connection (23), pressure and return line (3, 4) of power steering, connections of coolant hoses (18, 19, 21, 22), exhaust system and oil drain screw for leaks.

Number

Designation

Model 171
with engine
272

BA46.30-P-1002-01D

Connection fitting, high-pressure expansion hose/line to power steering pump

Nm

40

BA46.30-P-1012-01D

Clamp, hydraulic line to power steering pump reservoir

Nm

2

Number

Designation

Engine 272

BA01.45-P-1001-01M

Oil drain screw to oil pan

Nm

30

BA01.45-P-1004-01M

Bolt, power steering pressure line to oil pan

M6

Nm

10

Number

Designation

Engine 272

BA83.55-P-1001-01M

Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

Nm

20

Number

Designation

Model
171

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

-

M12

Nm

68

Number

Designation

Model 163, 170, 171, 202, 203, 204, 207, 208, 209, 210, 212, 230
with transmission 716.6

BA25.20-P-1002-01B

Union nut for clutch operating system line on hose

Nm

16

Number

Designation

Engine
272
in model
171

BA49.10-P-1001-01N

Bolt, catalytic converter to exhaust manifold

Nm

20

Number

Designation

Engine 272

BA07.03-P-1001-01B

Union nut, fuel line to fuel distributor

Nm

20

BA07.03-P-1004-01B

Protective cap on service valve

Plastic

Nm

2

Metal

Nm

15

Number

Designation

Trans-mission
716.6

BA26.40-P-1003-01C

Oil filler plug

Nm

35

BA26.40-P-1004-01C

Oil drain screw

Nm

30

Number

Designation

Engine
272 in model 171

BA22.10-P-1006-01O

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Engine
272.920/921/922/
923/940/941/942/
943/944/945/946/
947/949/951/952/
960/961/963/964/
965/966/967/968/
969/970/972/973/
974/980/982/983/
984/985/988
(Shortened maintenance interval)

Engine
272.920/921/922/
923/940/941/942/
943/944/945/946/
947/949/951/952/
960/961/963/964/
965/966/967/968/
969/970/972/973/
974/980/982/983/
984/985/988
(Maximum maintenance interval)

BF18.00-P-1001-01M

Engine oil

Filling capacity with oil filter

Liters

8,0

8,0

Specifications for service products

Sheet

-

-

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Number

Designation

Transmission
716.640/641/644/646/649, 716.653/654/655/656/657/658/66/67

BF26.10-P-1001-01C

Gear oil

Filling capacity

Liters

1.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-10A