Remove/install engine with transmission

AR01.10-S-2401SV

Remove/install engine with transmission

14.2.12

 

Remove/install

 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

 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

 Danger!

Risk of death caused by vehicle slipping or toppling off 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 injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 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 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

 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.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-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 fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

 Danger!

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.

AS83.00-Z-0001-01A



Notes on coolant

All engines

AH20.00-N-2080-01A



Brake fluid notes

All models

AH42.50-P-0001-01A



Notes on battery

All models

AH54.10-P-0001-01A

1

Disconnect ground line from battery

AR54.10-S-0003S

2

Remove front module (1)

AR88.30-S-1064S

3

Reduce fuel pressure through service valve

AR07.03-S-1460-01SV

 Pressure hose

*119589046300

4

Disconnect hose and line connections

AR01.10-S-2400-02SV

 Set of stop plugs

*129589009100

5

Detach shift cable (17) from transmission

 Pry off shift cable (17) from ball head and remove laterally from guide (arrow).

 Installation: Grease ball head and replace locking plate

Long-life grease

*BR00.45-Z-1001-06A

6

Detach exhaust system at exhaust manifold

AR49.10-S-7140-03SV



Checking

7

Check riveted nuts at exhaust manifold

 if necessary:



Replace riveted nuts at exhaust manifold

AR49.10-S-5531-01SV

8

Install transmission support

AR01.10-S-2400-04S

 Holding device

*639589006200

9

Remove rear engine crossmember (18)

 The rear engine crossmember (18) is removed with the mount. Proceed by first removing the screws (19).



*BA22.10-N-1003-01Q



*BA22.10-N-1004-01Q

 Torque wrench

*001589722100

10

Secure vehicle on vehicle lift

 When lowering the lifting platform, make sure the vehicle is secured to prevent damage.

AR00.60-S-0100S

11

Remove fitted bolts (23)

 Secure propeller shaft (22) outside of the working area.

Model 639 with transmission 716.6 without code ZG2



*BA41.10-N-1001-01L

Model 639 with transmission 716.6 with code ZG2



*BA41.10-N-1007-01L

 Torque wrench

*001589722100

12

Remove engine with transmission (2) using the removal fixture

AR01.10-S-2400-01SV

 Strut

*639589016300

 Adapter plate

*112589016200

 C-bracket

*639589016200

13

Install in the reverse order

14

Check shift cable (17) for ease of access

 if necessary:



Adjust cable of automatic transmission

AR27.60-S-1470S

15

Read out fault memory

 If necessary, delete DTC memory.



Connect STAR DIAGNOSIS and read out fault memory

Model 639

AD00.00-S-2000-04S

16

Check for leaks at all terminal blocks

 Carry out a visual inspection only.

17

Carry out engine test run

Number

Designation

Engine
112.951/
976
in model 639

BA22.10-N-1003-01Q

Bolt or nut, rear engine mount to transmission

M10

Nm

40

BA22.10-N-1004-01Q

Bolt, transmission carrier to longitudinal member

Nm

40

Number

Designation

Model
636, 639 with transmission 716.6 without code ZG2

BA41.10-N-1001-01L

Fitted bolt connecting propeller shaft to transmission

Stage 1

Nm

15

Stage 2

°

90

BA41.10-N-1007-01L

Fitted bolt connecting propeller shaft to transfer case

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

Model
639 with transmission 716.6 with code ZG2 up to VIN 195159

Model 639 with transmission 716.6 with code ZG2 from VIN 195160

BA41.10-N-1001-01L

Fitted bolt connecting propeller shaft to transmission

Stage 1

Nm

-

-

Stage 2

°

-

-

BA41.10-N-1007-01L

Fitted bolt connecting propeller shaft to transfer case

Stage 1

Nm

15

15

Stage 2

°

90

90

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11