Remove, install engine with transmission

AR01.10-P-2401FG

Remove, install engine with transmission

20.3.06

 

Remove/install

1

Remove front drive shafts

AR33.30-P-0620FG

2

Remove lower transmission bearing

AR26.10-P-0031FF

3

Detach lower engine compartment paneling

AR61.20-P-1105FF

4.1

Detach slave cylinder at transmission

Only for transmission 717.473

AR25.20-P-0150-01FF



*BA25.20-P-1002-01D

5

Remove exhaust flex pipe

AR49.10-P-7170FF

6

Drain coolant

AR20.00-P-1142FG

7.1

Remove poly-V-belt

For vehicles with Code (I01) Air conditioning Plus or Code (I77) Manual AC

AR13.22-P-1202FG

8.1

Remove the refrigerant compressor

For vehicles with Code (I01) Air conditioning Plus or Code (I77) Manual AC

AR83.55-P-5300-04FG



*BA83.55-P-1002-01L



*BA83.55-P-1004-01L

9

Detach bottom coolant hose (1) at radiator

 Collect coolant which flows out in a suitable vessel.

10

Lower vehicle

11

Remove paneling on center piece in front of the windshield

AR88.00-P-2792FF

12

Remove battery tray

AR54.00-P-0002FF

13

Remove control unit for Electronic Diesel System (EDS)

AR07.08-P-7006FF

14.1

Disconnect connector for pressure differential sensor (DPF) (26) at pressure differential sensor (DPF) (B28/8)

On vehicles with Code (K13) Diesel particulate filter

15.1

Disconnect temperature sensor connector upstream diesel particulate filter (B19/9x1) and temperature sensor connector upstream turbocharger (B19/11x1)

On vehicles with Code (K13) Diesel particulate filter

16.1

Unscrew bolt (25)

On vehicles with Code (K13) Diesel particulate filter

17

Disconnect engine wiring harness

AR01.00-P-2410-02FG



*BA15.40-P-1001-01L

18.1

Detach shift cables from transmission.

Only for transmission 717.473

AR26.60-P-6627-01FG

19

Loosen hose clamps (2) for coolant hoses (3) and detach coolant hoses (3)

 Collect coolant which flows out in a suitable vessel.

 Installation: Do not interchange the coolant hoses (3).

20

Loosen hose clamp (4) and detach charge air hose (5)

21

Loosen hose clamp (6) and detach charge air hose (7)

22

Detach top coolant hose (8) at radiator

 Collect coolant which flows out in a suitable vessel.

23

Remove coolant hose (9) on expansion reservoir (10)

24

Unlock brake booster (11) vacuum line on the vacuum pump and detach

 Actuate brake pedal a number of times in order to remove any vacuum present.

25

Remove clip for brake booster (11) vacuum line on bracket (12) and detach vacuum line (13) at brake booster (11) vacuum line

26

Remove coolant hose (14) from coolant pipe (15).

 Collect coolant which flows out in a suitable vessel.

27

Remove bolts (16)

28

Raise vehicle

29

Position major assembly lifting platform with support fixture

 Ensure correct seating of the major assembly lifting platform with support fixture on the engine (23) and
transmission (22).

AR01.10-P-2400-06FG

Aggregate lifting table (Master Gear 0.5)

*WE58.40-Z-1009-05A

30

Unscrew nuts (17, 18) and remove engine support (19)

 Installation: Replace self-locking
nuts (17, 18).



*BA22.10-P-1003-01Q



*BA22.10-P-1006-01Q

31

Unscrew bolt (20) and nuts (21)

 Installation: Replace self-locking nuts (21) and bolt (20).



*BA26.00-P-1002-01D



*BA26.00-P-1003-01D

32

Lower engine (23) and transmission (22) with major assembly lifting platform using the support fixture

 When lowering the engine (23) with transmission (22) ensure unobstructed movement at the body otherwise the body can be damaged.

 When lowering the engine (23) with transmission (22) loosen the transmission bearing (24) from the transmission (22) using a suitable screwdriver.

Aggregate lifting table (Master Gear 0.5)

*WE58.40-Z-1009-05A

33

Install in the reverse order

Number

Designation

Engine
639.939

BA15.40-P-1001-01L

Cable to alternator circuit B+

Nm

15

Number

Designation

Engine
639.9

BA22.10-P-1003-01Q

Nut connecting engine bracket to engine mount

Nm

48

BA22.10-P-1006-01Q

Nut connecting engine bracket to bracket

Nm

45

Number

Designation

Model
454.0

BA25.20-P-1002-01D

Torx bolt connecting clutch slave cylinder to transmission

Nm

18

Number

Designation

Trans-mission
717 except 717.478

BA26.00-P-1002-01D

Bolt connecting transmission mount to transmission

Nm

41

BA26.00-P-1003-01D

Nut connecting transmission bearing to transmission

Nm

41

Number

Designation

Engine
639.939

BA83.55-P-1002-01L

Torx bolt connecting refrigerant compressor to crankcase

Nm

20

BA83.55-P-1004-01L

Torx bolt connecting refrigerant compressor to oil pan

Nm

20

WE58.40-Z-1009-05A

Major assembly lifting platform