Remove/install engine

AR01.10-P-2400V

Remove/install engine

04.05.2018

Engine

271 in model 171 with transmission 716.6

Modification notes

25.06.2010

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

BA41.10-P-1001-01A

25.06.2010

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

BA41.10-P-1001-01A

1

Engine cover

5

Vacuum line

9

Return flow pipe

2

Engine air intake duct

6

Power steering pump reservoir

13

Power steering oil line

3

Brake booster vacuum line

7

Power steering pressure line

14

Screw

4

Fuel line

8

Union nut

Y58/1

Purge control valve

15

Bolts

18

Bolts

27

Coolant hose

16

Underfloor catalytic converter

24

Coolant hose

A9

Refrigerant compressor

17

Exhaust manifold with CAT

25

Coolant pipe on cylinder head

A9x1

Refrigerant compressor connector

10

Bolts

20

Shift rod

26

Coolant hose

11

Pressure connection fitting

21

Retaining ring

28

Coolant hose

12

Charge air duct

22

Shift rod

29

Bolts

19

Safety bolt

23

Clutch operation hydraulic line

M16/6

Throttle valve actuator

 

Remove/install

 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

 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.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 Danger

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Detach ground line from battery

AR54.10-P-0003V

Topical note

Notes on battery

AH54.10-P-0001-01A

2

Pull engine cover (1) upwards off cylinder head cover

 When placing engine cover (1), ensure that seal is correctly seated at the oil filler neck. The seal should not be pressed down by the engine cover (1), but must lie against the engine cover (1).

3

Remove engine air intake duct (2)

4

Remove wideband silencer

AR09.41-P-6825V

5

Remove poly-V belt

AR13.22-P-1202V

6

Remove fan shroud

AR20.40-P-6800VK

7

Remove vacuum line (3) of brake booster

AR43.10-P-0355V

8

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01V

 Pressure hose

*119589046300

9

Detach fuel line (4) from fuel distributor

 Collect escaping fuel and seal connections with  stop plugs.

 Installation: Check bolted connection for leaktightness.

 Fuel feed line to fuel distributor

*BA07.52-P-1002-01B

 Record plug

*129589009100

10

Detach vacuum line (5) from purging switchover valve (Y58/1)

11

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

12

Suction off oil from the reservoir (6) of the power steering pump

 Hand pump

*210589007100

13

Detach pressure line (7) for power steering from power steering pump by unscrewing union nut (8)

 Catch escaping oil with rags and close line connections with  stop plugs.

 Installation: Replace sealing ring.

 Connection fitting from high-pressure line to power steering pump

*BA46.30-P-1002-01D

 Record plug

*129589009100

14

Detach return line (9) from reservoir (6) of power steering pump

 Catch escaping oil with rags and close line connections with  stop plugs.

 Record plug

*129589009100

15

Remove screw/bolts (10) and detach pressure connection (11) from throttle valve actuator (M16/6)

 Screw/bolt, charge air duct downstream of charge air cooler to pressure damper

*BA09.41-P-1004-02A

16

Drain coolant at radiator

AR20.00-P-1142V

17

Extract/drain engine oil



AP18.00-P-0101AB

18

Detach engine wiring harness to remove engine

AR01.00-P-2410-02VA

19

Detach charge air duct (12) from charge air cooler and take out with pressure connection (11)

20

Detach power steering oil line (13) from oil pan by unscrewing screw/bolt (14)

 Bolt, power steering oil line to oil pan

*BA01.45-P-1002-01H

21

Detach refrigerant compressor (A9); to do this step unscrew screw/bolts (15)

Model 171 with engine 271 with transmission 716.6
with code 581 (Automatic air conditioning)

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

 Bolt, refrigerant compressor to bracket

*BA83.55-P-1001-01G

 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.

AS00.00-Z-0002-01A

22

Detach underfloor catalytic converter (16) from exhaust manifold with catalytic converter (17) by unscrewing screw/bolt (18)

 Bolt connecting underfloor catalytic converter to exhaust manifold with catalytic converter

*BA49.10-P-1012-01K

23

Detach propeller shaft at transmission

AR41.10-P-0050-02V

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

*BA41.10-P-1001-01A

24

Support transmission with transmission jack and transmission plate, and remove rear engine mount

AR22.10-P-1160VK

25

Release safety bolts (19) and pull out

26

Unhook shift rod (20) from transmission

27

Lower transmission



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

 Lower transmission until base of the rear engine mount is lying at the transmission on the engine crossmember. Lower transmission jack and drive under vehicle.

28

Unhook retaining ring (21) and detach shift rod (22) at transmission

29

Disconnect hydraulic line (23) of clutch operation

Topical note

Brake fluid notes

AH42.50-P-0001-01A

 Seal off connections using  stop plugs.

 Union nut for clutch operating system line on hose

*BA25.20-P-1002-01B

 Record plug

*129589009100

30

Detach coolant hose (24) from coolant pipe (25) at cylinder head

 Check condition of the coolant hose (24). Replace it if necessary.

31

Remove coolant hose (26)

 Check condition of coolant hose (26) and replace if necessary.

32

Unclip coolant hose (27) from bracket and detach from coolant pipe (25) at cylinder head

 Check condition of coolant hose (27) and replace if necessary.

33

Detach coolant hose (28) from crankcase

 Check condition of coolant hose (28) and replace if necessary.

34

Detach both engine mounts from front axle carrier by unscrewing screw/bolts (29)

 Screw/bolt, front engine mount to front axle carrier

*BA22.10-P-1006-01O

35

Lift out engine


Lift out engine carefully and ensure that the engine does not touch the partition wall.
Cable, lines and the partition wall will be damaged otherwise when lifting out the engine .

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

 Commercially available devices/tools
Load tilter

36

Install in the reverse order

37

Bleed clutch operating system

AR25.20-P-0070V

38

Check transmission oil level

 Correct oil level = 10 mm below the lower edge of the filler opening. Carry out measurement e.g. with an angled Allen wrench.

 Transmission oil

*BF26.10-P-1001-01C

 Oil filler screw

*BA26.40-P-1003-01C

 Drain screw

*BA26.40-P-1004-01C

39

Fill power steering pump and bleed

AR46.30-P-0010V

 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

40

Carry out an engine test run

 Check fuel line threaded connections (4), power steering pressure and return lines (7, 9), clutch operating mechanism hydraulic line (23), coolant hose connections (24, 26, 27, 28), exhaust system, oil drain screw and coolant drain plug for leaktightness.

 Oil pan

Number

Designation

Engine 271

BA01.45-P-1002-01H

Bolt, power steering oil line to oil pan

M6

Nm

10

 Fuel distributor

Number

Designation

Engine 271.9

BA07.52-P-1002-01B

Fuel feed line to fuel distributor

Nm

24

 Charge air duct

Number

Designation

Engine 271

BA09.41-P-1004-02A

Screw/bolt, charge air duct downstream of charge air cooler to pressure damper

Nm

8

 Engine suspension, engine mounts, engine supports

Number

Designation

Engine 271 in model 171

BA22.10-P-1006-01O

Screw/bolt, front engine mount to front axle carrier

Nm

35

 Clutch operating system

Number

Designation

Transmission 716.6 all models (except in model 211)

BA25.20-P-1002-01B

Union nut for clutch operating system line on hose

Nm

16

 Housing

Number

Designation

Transmission 716.6

BA26.40-P-1003-01C

Oil filler screw

Nm

35

 Housing

Number

Designation

Transmission 716.6

BA26.40-P-1004-01C

Drain screw

Nm

30

 Propeller shaft

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

 Power steering pump

Number

Designation

Model 171 with engine 271

BA46.30-P-1002-01D

Connection fitting from high-pressure line to power steering pump

Nm

40

 Exhaust system

Number

Designation

Engine 271 in model 171

BA49.10-P-1012-01K

Bolt connecting underfloor catalytic converter to exhaust manifold with catalytic converter

Nm

20

 Refrigerant compressor

Number

Designation

Engine 271 in model 171, 172, 203, 209, 211, 212

BA83.55-P-1001-01G

Bolt, refrigerant compressor to bracket

Nm

20

 Complete transmission

Number

Designation

Transmission 716.60 in model 203, 204, 207, 211, 212
Transmission 716.61 in model 204, 207, 212
Transmission 716.62 in model 203, 209, 211
Transmission 716.63 in model 171, 203, 204, 209, 211, 212

BF26.10-P-1001-01C

Transmission oil

Filling capacity

Liter

1,2

Sheet

BB00.40-P-0235-10A