Remove/install engine

AR01.10-P-2400VC

Remove/install engine

18.8.15

Engine

271 in model 171 with transmission 722.6

Modification notes

25.6.10

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

BA41.10-P-1001-01A

25.6.10

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

BA41.10-P-1001-01A

1

Engine cover

6

Power steering expansion reservoir

11

Pressure connection fitting

2

Engine air intake duct

7

Power steering pressure line

12

Charge air duct

3

Brake booster vacuum line

8

Union nut

M16/6

Throttle valve actuator

4

Fuel line

9

Power steering return line

Y58/1

Purging switchover valve

5

Vacuum line

10

Screw/bolts

7

Power steering pressure line

16

Exhaust manifold with CAT

20

Range selector lever

13

Screw/bolt

17

Screw/bolts

A9

Refrigerant compressor

14

Screw/bolts

18

Retaining clip

A9x1

Refrigerant compressor connector

15

Underfloor catalytic converter

19

Shift rod

21

Bracket for oil lines

24

Radiator

27

Coolant hose

22

Automatic transmission oil line

25

Coolant hose

28

Coolant hose

23

Automatic transmission oil line

26

Coolant pipe on cylinder head

29

Coolant hose

30

Screw/bolt

 

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

 Danger !

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



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

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

8

Remove vacuum line (3) of brake booster

AR43.10-P-0355V

9

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01V

 Pressure hose

*119589046300

10

Detach fuel line (4) from fuel distributor

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

 Fuel feed line to fuel distributor

*BA07.52-P-1002-01B

 Record plug

*129589009100

11

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

12

Suction off oil out of power steering expansion reservoir (6)

 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) of power steering from expansion reservoir (6) for the power steering

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

 Clamp, hydraulic line to power steering pump reservoir

*BA46.30-P-1012-01D

 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

Raise vehicle

AR00.60-P-1000V

17

Detach lower engine compartment paneling

AR61.20-P-1105V

18

Drain coolant at radiator

AR20.00-P-1142V

19

Drain engine oil



AP18.00-P-0101AB

 Installation: Replace sealing ring.

 Oil drain screw to oil pan

*BA01.45-P-1007-01H

 Engine oil

*BF18.00-P-1001-01L

20

Detach engine wiring harness to remove engine

AR01.00-P-2410-02VC

21

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

22

Detach pressure line (7) of power steering from oil pan by unscrewing Screw/bolt (13)

 Bolt, power steering oil line to oil pan

*BA01.45-P-1002-01H

23

Detach refrigerant compressor (A9) from timing case cover and engine support; to do this unscrew the screw/bolts (14)

Model 171 with engine 271 with transmission 722.6
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

 Danger !

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

24

Detach underfloor catalytic converter (15) from exhaust manifold with catalytic converter (16); to do this unscrew screw/bolt (17)

 Installation: Clean connecting points of combustion and corrosion residues; replace screw/bolts (17).

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

*BA49.10-P-1012-01K

25

Detach propeller shaft from output flange of automatic transmission

AR41.10-P-0050-02V

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

*BA41.10-P-1001-01A

26

Detach retaining clip (18) and unhook shift rod (19) at range selector lever (20)

 Installation: Replace retaining clip (18).

27

Remove rear engine mount

AR22.10-P-1160VK



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

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

28

Detach bracket (21) for oil lines (22, 23) from automatic transmission

 Bolt, dual clamp to oil line

*BA27.55-P-1004-01B

29

Detach oil line (22) for automatic transmission from radiator at bottom (24)


Seal off connections using  stop plugs.
Damage can occur to the automatic transmission otherwise due to soiling.

 Installation: Replace sealing ring. Ensure oil line (22) for automatic transmission is fitted correctly to the radiator (24).

 Record plug

*129589009100

30

Detach oil line (23) for automatic transmission from radiator at top (24)


Seal off connections using  stop plugs.
Damage can occur to the automatic transmission otherwise due to soiling.

 Installation: Replace sealing ring. Ensure oil line (23) for automatic transmission is fitted correctly to radiator (24).

 Record plug

*129589009100

31

Detach coolant hose (25) from coolant pipe (26) at cylinder head

 Check condition of coolant hose (25). Replace it if necessary.

32

Remove coolant hose (27)

 Check condition of coolant hose (27). Replace it if necessary.

33

Unclip coolant hose (28) from bracket and detach from coolant pipe (26) at cylinder head

 Check condition of coolant hose (28). Replace it if necessary.

34

Detach coolant hose (29) from connection fittings at cylinder crankcase

 Check condition of coolant hose (29). Replace it if necessary.

35

Detach both engine mounts from front axle carrier by unscrewing screw/bolts (30)

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

*BA22.10-P-1006-01O

36

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

37

Install in the reverse order

38

Check oil level in automatic transmission, adjust to correct level if necessary

AR27.00-P-0100AC

39

Fill power steering pump and bleed

AR46.30-P-0010V

 Danger !

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 bolted connection for fuel line oil lines (22, 23) of the A/T, pressure and return line (7, 9) of the P/S, connections of the coolant hoses (25, 27, 28, 29), 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

 Oil pan

Number

Designation

Engine 271

BA01.45-P-1007-01H

Oil drain screw to oil pan

M14

Nm

30

 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

 Transmission oil cooling

Number

Designation

Transmission 722.6 in model 170, 171, 203, 209, 210, 215, 219, 220, 230, 240

BA27.55-P-1004-01B

Bolt, dual clamp to oil line

Nm

8

 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

 Power steering pump

Number

Designation

Model 171 with engine 271

BA46.30-P-1012-01D

Clamp, hydraulic line to power steering pump reservoir

Nm

2

 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

 Filling capacities for engine lubrication system

Number

Designation

Engine 271
(Shortened maintenance interval)

Engine 271
(Maximum maintenance interval)

BF18.00-P-1001-01L

Engine oil

Filling capacity without filter

Liter

–

–

Filling capacity with filter

Liter

5,5

5,5

Sheet

-

-

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-31A

-

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-51A

-

Sheet

BB00.40-P-0229-52A

-