Remove/install engine

AR01.10-D-2400US

Remove/install engine

17.10.11

 

Remove/install

 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



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Secure vehicle so that it does not roll away and move the automatic selector lever to the neutral position

2

Disconnect battery ground line

AR54.10-D-0003SD

3

Remove engine hood

AR88.40-D-3000SD

4

Detach right bracket for air filter housing

AR09.10-D-1150-03SF

5

Remove air intake hose

AR09.10-D-8030US

6

Remove injection system control unit

AR07.08-D-7008US

7

Remove front module

AR88.30-D-1064SD

8

Detach coolant hose (2) at coolant pump

 Coolant hose (2) with Henn coupling. Collect coolant which flows out.

AR09.41-P-1311-01AL

9

Detach oil dipstick guide tube (3) of the automatic transmission at the cylinder head cover



*BA27.10-N-1001-04B

10

Reduce fuel pressure with pressure hose via the service valve

AR07.03-D-1460-01US



*BA07.03-N-1003-01G



*119589046300

11

Disconnect fuel line (5) at the fuel distributor (4) and seal connections with suitable stop plugs

 Catch escaping fuel with an absorbent rag.



*BA07.03-N-1001-01G

12

Disconnect hose and line connections

AR01.10-D-2400-02US



*129589009100

13

Remove starter

AR15.30-D-7100US

14

Detach the left and the right catalytic converter (7) at the exhaust manifolds (6) and at the brackets (8)

 Installation: Check rivet nuts in the exhaust manifolds (6) and replace them if required.

See 

Replace rivet nuts in exhaust manifold (6)

AR49.10-D-5531-01US



*103589013900



*BA49.10-N-1001-01L

15

Detach the stabilizer bar at the frame-Model integral support and swivel it downwards

Only in vehicles with code (C40) Front axle stabilizer bar or code (C45) Reinforced front axle stabilizer bar and vehicles without code (ZG1) All-wheel drive, engageable or without code (ZG2) All-wheel drive, permanent or without code (ZG3) All-wheel drive gear reduction or without code (ZG4) Permanent all-wheel drive with gear reduction

AR32.20-D-0350H

16

Detach torque converter at the clutch plate

AR27.20-D-0100-01US



*112589034000



*BA27.20-N-1004-01C

17

Remove engine (1) with removal fixture

AR01.10-D-2400-01US



*906589016200



*BA22.10-N-1001-01S



*BA27.10-N-1003-04B

Transmission jack 2.0-7.0 t
gotis://H_00.10_01.0

Transmission plate for passenger cars and commercial vehicles
gotis://A_25/35/49_02.0

Boom crane
gotis://H_00.12_03.0

Engine support device, engine hoist
gotis://A_01_09.0

18

Install in the reverse order

Number

Designation

Engine
272
in model
906

BA07.03-N-1001-01G

Union nut, fuel line to fuel distributor

Nm

24

BA07.03-N-1003-01G

Protective cap on service valve

Nm

15

Number

Designation

Engine 272.9

BA22.10-N-1001-01S

Screw/bolt, front engine mount to front axle carrier

Nm

58

Number

Designation

Transmission 722.683/684/
685

BA27.10-N-1001-04B

Screw/bolt, oil filler pipe to cylinder head

Nm

12

BA27.10-N-1003-04B

Bolt connecting transmission housing to engine

Nm

38

Number

Designation

Model
906 with
transmission
722.683/684/
685/686

BA27.20-N-1004-01C

Screw/bolt, torque converter to drive plate

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

Number

Designation

Engine
272.979
in model
906

BA49.10-N-1001-01L

Screw/bolt, catalytic converter to exhaust manifold

Nm

20