Remove/install engine with transmission

AR01.10-D-2401TSV

Remove/install engine with transmission

15.04.2020

Engine

642 in model 907

Modification notes

15.07.2019

Reference link changed

Operation step 12

Shown with transmission 722.9

1

Clip

2

Transmission

3

Rear engine support

4

Transmission oil lines (with transmission 722.9)

6

Motor

5

Crossmember

6

Motor

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 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 poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

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 rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 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

 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

 Warning

Risk of burn injuries and scalding when working on AdBlue(R) lines and the component parts attached to them. Risk of injury to skin and eyes when handling AdBlue(R). Risk of poisoning caused by swallowing AdBlue(R)

Pour AdBlue® only into suitable containers. Wait until the pressure is released before starting any work on the exhaust aftertreatment system.

AS49.20-Z-0002-01A

 Warning

Risk of burns and scalding when handling hot fluids and components they come into contact with. Risk of injury to skin and eyes when handling hot fluids.

Wear protective gloves, protective clothing and safety glasses, if necessary. Pour hot fluids in suitable containers only.

AS00.00-Z-0033-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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.

AS42.50-Z-0001-01A

 Caution

Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil

Wear protective gloves, protective clothing and safety glasses.
Do not pour transmission oil into beverage bottles.

AS00.40-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on carrying out repair work in the vehicle interior

AH68.00-N-0001-01S

Topical note

Notes on use, material properties and handling of NOx reducing agent

AH49.20-N-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Brake fluid notes

AH42.50-P-0001-01A

 

Remove/install

1

Shift respective transmission (2) to neutral position.

2

Detach ground line of on-board electrical system battery.

AR54.10-D-0029TS

3

Disconnect ground line of auxiliary battery.

Model 907 with code E2I (Auxiliary battery for retrofit consumers, interior)

AR54.10-D-0004TS

Model 907 with code E2M (Auxiliary battery for retrofit consumer, engine compartment) except code E2I (Auxiliary battery for retrofit consumer, interior)

AR54.10-D-0004TSR

4

Remove hood.

AR88.40-D-3000TS

5

Remove brackets of air filter housing.

AR09.10-D-1149TS

6

Remove air intake pipe on exhaust gas turbocharger.

AR09.10-D-8131TSV

7

Remove front bumper.

AR88.20-D-2000TS

8

Remove both front lamp units.

AR82.10-D-4733TS

9

Discharge air conditioning system.

Engine 642 in model 907
with code HH4 (THERMOTRONIC automatic climate control)
Engine 642 in model 907
with code HH9 (Air conditioner, automatic heater control)

AR83.30-D-1760TS

10

Remove engine compartment lining.

If installed.

AR61.20-D-1105TS

11

Remove underbody paneling.

If installed.

AR61.30-D-1001TS

12

Secure vehicle on vehicle lift.

AR00.60-D-0100-01TS

 Commercially available devices/tools
Tensioning straps

13

Drain off coolant.

AR20.00-D-1142TSR

14

Remove NOx sensor upstream of SCR catalytic converter from diesel particulate filter.

AR49.20-D-2063TSR

15

Open clamp (1) and remove SCR catalytic converter from diesel particulate filter.

 Clamp, diesel particulate filter to SCR catalytic converter

*BA49.20-N-1003-02TSR

16

Remove charge air hose upstream of charge air cooler.

AR09.41-D-8621TSR

17

Remove charge air hose downstream of charge air cooler.

AR09.41-D-8625TSR

18

Remove shift cables from manual transmission.

Engine 642 in model 907 with transmission 711.6

AR26.60-D-6626-01TS

Long-life grease

*BR00.45-Z-1001-06A

19

Remove propeller shaft and hang to one side outside of working area.

AR41.10-D-0050TS

20

Remove lines and hoses to remove engine (6) while engine is lifted.

AR01.10-D-2400-15TSV

 Commercially available devices/tools
Collecting pan

 Record plug

*129589009100

21

Disconnect electrical connector of automatic transmission.

Engine 642 in model 907 with transmission 722.9

AR27.19-D-0750-02TS

 Engine 642 in model 907 with transmission 722.9Bolt, heat shield to transmission housing

*BA27.40-N-1007-01I

22

Remove electric lines to remove engine (6) while engine is lifted.

AR01.10-D-2400-16TSV

 M6

*BA00.10-N-1002-01A

 Nut, positive line to connection for connecting point

*BA54.10-N-1004-01TS

23

Insert suitable wooden block between transmission (2) and rear engine carrier (3).

24

Remove rear engine mount from transmission (2).

AR22.10-D-1160TSR

25

Remove front crossmember.

AR62.30-D-0007TS

26

Remove lines and hoses to remove engine (6) while engine is lowered.

AR01.10-D-2400-15TSV



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Commercially available devices/tools
Collecting pan

 Screw, refrigerant line (suction line) to refrigerant line (suction line)

*BA83.30-N-1004-01TS

 Nut, refrigerant condenser to refrigerant line

*BA83.30-N-1007-01TS

 Hose clamp pliers

*454589003700

 Record plug

*129589009100

27

Disconnect transmission oil lines (4) from front connecting points.

Engine 642 in model 907 with transmission 722.9

AR27.10-D-0501-03TSF

 Commercially available devices/tools
Collecting pan

Assembly cleaner

*BR00.45-Z-1028-04A

 Record plug

*129589009100

28

Remove hood catch crossmember with radiator unit.

AR88.00-D-2303-01TS

 Bolt, crossmember for hood catch to front upper longitudinal member

*BA88.00-N-1001-05TS

 Bolt, crossmember for hood catch to front upper inner longitudinal member

*BA88.00-N-1002-05TS

 Bolt, crossmember for hood catch to front longitudinal member

*BA88.00-N-1003-05TS

 Bolt, lower section of hood catch to assembly carrier

*BA88.40-N-1004-01TS

 Clip remover

*452589016300

 Record plug

*129589009100

29

Remove crossmember (5).

If installed.

 For this purpose unscrew nuts.

30

Remove electric lines to remove engine (6) while engine is lowered.

AR01.10-D-2400-16TSV

 Nut, differential pressure sensor to bracket

*BA07.04-N-1008-02TSV

 Nut, positive line to connection for battery clamp

*BA54.10-N-1005-01TS

31

Remove engine (6) with transmission (2) using engine removal fixture.

AR01.10-D-2401-01TSV



000 588 04 62 00 Removal fixture

WS01.00-N-3014B

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

*BA22.10-N-1004-01TSR

 Support plate

*906589016200

32

Install in the reverse order

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Sensors

Number

Designation

Engine 642 in model 907

BA07.04-N-1008-02TSV

Nut, differential pressure sensor to bracket

Nm

10

 Engine mounts, engine supports

Number

Designation

Engine 642 in model 907

BA22.10-N-1004-01TSR

Screw/bolt, front engine mount to front axle carrier

Nm

58

 Housing

Number

Designation

Transmission 722.9

BA27.40-N-1007-01I

Bolt, heat shield to transmission housing

Nm

9

 Diesel particulate filter

Number

Designation

Model 907 with engine 642

BA49.20-N-1003-02TSR

Clamp, diesel particulate filter to SCR catalytic converter

Nm

35

 Battery

Number

Designation

Model 907

BA54.10-N-1004-01TS

Nut, positive line to connection for connecting point

Nm

16

 Battery

Number

Designation

Model 907

BA54.10-N-1005-01TS

Nut, positive line to connection for battery clamp

Nm

16

 Air conditioning

Number

Designation

Model 907 with engine 274, 642, 651
Model 910 with engine 651

BA83.30-N-1004-01TS

Screw, refrigerant line (suction line) to refrigerant line (suction line)

Nm

20

 Air conditioning

Number

Designation

Model 907 with engine 274, 642, 651
Model 910 with engine 651

BA83.30-N-1007-01TS

Nut, refrigerant condenser to refrigerant line

Nm

12

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1001-05TS

Bolt, crossmember for hood catch to front upper longitudinal member

Nm

10

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1002-05TS

Bolt, crossmember for hood catch to front upper inner longitudinal member

Nm

10

 Cross member for hood catch

Number

Designation

Model 907, 910

BA88.00-N-1003-05TS

Bolt, crossmember for hood catch to front longitudinal member

Nm

20

 Engine hood

Number

Designation

Model 907, 910

BA88.40-N-1004-01TS

Bolt, lower section of hood catch to assembly carrier

Nm

9

Repair materials

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1028-04A

Assembly cleaner

A 000 986 56 01