Remove/install engine with transmission

AR01.10-P-2401MCD

Remove/install engine with transmission

17.04.2019

Engine

660.9 in model 451.3/4

1

Hose clamps

7

Coolant return flow line

13

Vacuum hose

2

Return fuel line

8

Coolant line feed line

14

Check valve

3

Fuel feed line

9

Coolant heater line

15

Brake booster vacuum line

4

Expansion clips

10

Nut

G2

Alternator

5

Cover

11

Electrical line

M1

Starter

6

Hose clamps

12

Nut

16

Screw

17

Torque support

18

Screw

19

Air supply ducting

20

Mount for transmission mounting

21

Bolts

22

Bolts

23

Right engine mount

 

Remove/install

 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

Topical note

Notes on coolant

AH20.00-N-2080-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

1

Remove right side paneling in trunk

AR68.30-P-4800MCC

2

Remove interior flap above engine

AR88.40-P-1100-03MCC

3

Disconnect ground line of battery

AR54.10-P-0003MCC

4

Remove fender liner in right rear fender

AR88.10-P-1400MCC

5

Lower vehicle with vehicle lift

6

Disconnect engine wiring harness on vehicle side

AR15.18-P-1000-02MCD

 Bolt, vacuum pump to cylinder head

*BA43.05-P-1002-01G

7

Release clamps (1), remove fuel return line (2) and fuel feed line (3) at corresponding line connections and seal with suitable stop plugs

 Installation: Replace clamps (1).

8

Drain off coolant

AR20.00-P-1142MCD

9

Remove rear axle crossmember together with control arms

AR35.15-P-0250MCC

10

Remove left and right rear axle shaft

AR35.30-P-0620MCC

11

Lower rear drive module

AR01.00-P-3050MCC

12

Remove expansion clips (4) and remove cover (5)

13

Remove poly-V belt for supercharger

In vehicles with code (I01) Air conditioning system Plus

AR13.21-P-1202MCD

14

Remove refrigerant compressor and secure at suitable location with a cable tie

In vehicles with code (I01) Air conditioning system Plus

AR83.55-P-5300-04MCD

 Bolt, refrigerant compressor to bracket

*BA83.55-P-1002-01I

 Bolt, refrigerant compressor, basic carriers

*BA83.55-P-1003-01I

15

Remove rear muffler

AR49.10-P-4823MCD

16

Remove electrical wiring harness at transmission

AR26.19-P-0001-05MCC

17

Release clamps (6) and remove coolant return line (7), coolant feed line (8) as well as coolant heater line (9) from corresponding coolant pipe

 Installation: Replace clamps (6).

18

Lower vehicle with vehicle lift

19

Unscrew nut (10) at alternator (G2) and remove electric line (11) from alternator (G2)

20

Unscrew nut (12) at starter (M1) and expose electric line (11)

21

Remove vacuum hose (13) at check valve (14)

22

Remove and expose brake booster vacuum line (15) at vacuum pump

23.1

Release EGR switchover valve at air filter housing and set down to one side with connected vacuum hoses as well as connected electrical connector

Model 451.3## /4## #K up to 452007

AR14.20-P-7660MCD

23.2

Disconnect vacuum hoses and electrical connector at EGR switchover valve

Model 451.3## /4## #K as of 452008

AR14.20-P-7660MCF

24

Disconnect vacuum hoses and electrical connector at left boost pressure regulator

Model 451.3##/4## #K up to 452007 with code 474 (Diesel particulate filter)

AR09.41-P-2004MCD

Model 451.3##/4## #K as of 452008

AR09.41-P-2004MCF

25

Unscrew screws of air filter housing at transmission and fully remove air filter housing upwards

26

Raise vehicle with vehicle lift

27

Remove screw (16) at torque support (17)

 Screw/bolt, torque support to front engine mount carrier

*BA22.10-P-1009-01N

28

Position major assembly lifting platform with universal major assembly mount under engine and transmission

AR01.10-P-2400-06MCC

 Mounting fixture

*451589006200

29

Unscrew screw (18) of air supply ducting (19) at transmission suspension mount (20)

30

Unscrew screws (21) of transmission suspension mount (20) at transmission

 Screws (21) can be accessed above left wheel arch.

 Bolt, transmission mount to transmission

*BA26.00-P-1002-01D

31

Unscrew screws (22) of right engine mount (23) at intermediate plate at cylinder head

 Screws (22) can be accessed above right wheel arch.

 Screw/bolt, right engine mount to engine support on cylinder head

*BA22.10-P-1007-01N

32

Carefully lower engine with transmission


Carefully lower and position engine with transmission.
Electric lines and hoses can otherwise become trapped.

 Aid of helper required.

33

Lift vehicle with vehicle lift to extent that engine with transmission can be pulled out under vehicle

34

Install in the reverse order

 Engine mounts, engine supports

Number

Designation

Engine 660.950/951

BA22.10-P-1007-01N

Screw/bolt, right engine mount to engine support on cylinder head

Nm

70

 Engine mounts, engine supports

Number

Designation

Engine 660.950/951

BA22.10-P-1009-01N

Screw/bolt, torque support to front engine mount carrier

Nm

115

 Manual transmission complete

Number

Designation

Transmission 717.48

BA26.00-P-1002-01D

Bolt, transmission mount to transmission

Nm

80

 Electric vacuum pump of brake booster

Number

Designation

Engine 660.950/951

BA43.05-P-1002-01G

Bolt, vacuum pump to cylinder head

Nm

10

 Refrigerant compressor

Number

Designation

Engine 660.950/951

BA83.55-P-1002-01I

Bolt, refrigerant compressor to bracket

Nm

20

 Refrigerant compressor

Number

Designation

Engine 660.950/951

BA83.55-P-1003-01I

Bolt, refrigerant compressor, basic carriers

Nm

20