S01.10-4577-09
1 | Propeller shaft | 3 | Selector lever cable | 5 | Nut | ||
2 | Shift cable | 4 | Coolant 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. | |
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. | |
Warning | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. | |
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. | |
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. | |
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. | |
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on coolant | ||
Topical note | Brake fluid notes | ||
| Remove/install | ||
1 | Remove ground line from battery | ||
2 | Remove front module | ||
3 | Remove engine cover | ||
4 | Disconnect hose and line connections | ||
Nut, power supply cable to plug connection box | |||
High pressure expansion hose to power steering pump | |||
Nut/bolt, bracket to front exhaust system | |||
Threaded connection, refrigerant line to refrigerant line | |||
MODEL 636, 639.7/8 with CODE HZ7 (Semi-automatically controlled air conditioning, TEMPMATIC in rear)Connection fitting from rear intake line to front intake line of rear air conditioning | |||
Model 636,639 with transmission 711.680Screw/bolt, manual transmission to engine | |||
Model 636, 639 with transmission 711.680Bolt, speed sensor for tachograph to transmission | |||
Model 639 with transmission 722.6Automatic transmission to engine | |||
Record plug | |||
5 | Remove engine crossmember at rear | ||
6 | Remove check strap from propeller shaft (1). | Engine 651 in model 639 | |
Bolt, check strap to underbody | |||
7 | Remove front propeller shaft intermediate bearing | Secure propeller shaft (1) to prevent it from falling. | |
Bolt, intermediate bearing connection to underbody | |||
8 | Remove screw/bolts of drive shaft (1) at transmission or at flexible coupling | Installation: Replace screw/bolts for drive shaft (1). | |
Fitted bolt connecting drive shaft to transmission | |||
Bolt, drive shaft to flexible coupling | |||
9 | Remove propeller shaft (1) from transmission or flexible coupling | Place propeller shaft (1) to one side and fasten to underfloor. | |
10 | Remove front axle transmission propeller shaft |
| |
11 | Remove shift cables (2) or selector lever cable (3) from transmission or automatic transmission | For this purpose remove ball sockets from ball heads. | |
Installation: Lightly grease the ball sockets and ball heads. | |||
Long-life grease | |||
12 | Disconnect cable tie of the shift cable (2) or the selector lever cable (3) | Installation: Replace cable tie. | |
13 | Remove shift cables (2) or selector lever cable (3) | ||
14 | Place shift cables (2) or selector lever cable (3) to one side and tie up | ||
15 | Disconnect plug coupling from electronic transmission control |
| |
16 | Secure vehicle on vehicle lift | ||
17 | Unscrew nuts (5) for coolant line (4) | ||
18 | Remove coolant line (4) from engine and remove on integral carrier | To do this open clamp and lay coolant line (4) to one side outside the working area. | |
19 | Remove primary catalytic converter on ATL | ||
20 | Remove engine with removal fixture | ||
Bolt, front engine mount to engine support | |||
Antifriction paste, rubber parts 2.5 kg, DBL 6867.00 | |||
C clamp | |||
Strut | |||
Adaptation | |||
Support plate | |||
21 | Install in the reverse order | ||
22 | Bleed clutch operating system |
| |
| Check | ||
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. | |
23.1 | Check shift cables (2) for ease of movement | MODEL 636, 639 with TRANSMISSION 711.6 | |
Depending on findings | |||
| |||
Adjust shift cables for manual transmission | |||
23.2 | Check selector lever cable (3) for ease of movement | Model 639 with transmission 722.6 | |
Depending on findings | |||
| |||
Adjust automatic transmission shift cable | |||
24 | Check for leak tightness with engine running | Visual inspection only. | |
25 | Perform run-in program after engine replacement | Only when replacing the engine. | |
Rear air conditioning |
Number | Designation | Model 636.7/8 | Model 639.7/8 | |
BA83.50-N-1002-01D | Connection fitting from rear intake line to front intake line of rear air conditioning | Nm | 8 | 8 |
129 589 00 91 00
Record plug
639 589 09 62 00
Adaptation
906 589 05 62 00
Support plate
639 589 01 62 00
C clamp
639 589 01 63 00
Strut
Referenced documents
- ah0000n000101a Notes on self-locking nuts and bolts
- ah2000n208001a Notes on coolant
- ah4250p000101a Brake fluid notes
- ar0060s0100s Secure vehicle on vehicle lift
- ar0110d240601we Perform run-in program after engine replacement
- ar0110s240001sj Remove/install engine with removal fixture
- ar0110s240002sj Disconnect/connect hose and line connections
- ar0110s2405sj Remove/install engine cover
- ar2210s1170s Remove/install rear engine cross member
- ar2520s0070s Bleed clutch operating system
- ar2660s6633sd Adjust shift cables for manual transmission
- ar2710s050001sv Disconnect/connect plug
- ar2760s1470s Adjust cable of automatic transmission
- ar4110s0070s Remove/install front axle transmission propeller shaft
- ar4910s5510sj Remove/install engine-side primary catalytic converter
- ar5410s0003s Disconnect/connect battery ground line
- ar8830s1064s Remove/install front module
- as0000z000201a Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.
- 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.
- as0000z001301a Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
- 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.