Remove/install engine with transmission

AR01.10-P-2401MFB

Remove/install engine with transmission

22.01.2020

Engine

608 in model 118, 177, 247 with transmission 711.63

Modification notes

29.10.2019

Document completely revised.

Shown on model 177

1

Electrical connector

13

Coolant hose

4

Fan

14

Vacuum line

5

Coolant hose

15

Vacuum pump

6

Coolant hose

31

Bolts

7

Refrigerant lines

32

Bolts

8

Nut

33

Coolant line

11

Fuel hoses

N37/7

NOx sensor control unit upstream of SCR catalytic converter

12

Coolant hose

Y129

AdBlue® metering valve

Shown on model 177

2

Cover

9

Coolant lines

3

Nut

10

Coolant hoses

7

Refrigerant lines

Shown on model 177

17

Caps (2 pieces)

21

Electrical connector

18

Nuts

22

Electrical connector

19.1

Electrical connector

23

Electrical line

19.2

Electrical connector

Shown on model 177

16

Electrical line

24

Locks

25

Coolant line

26

Bolts

27

Bolts

28

Connecting carrier

29

Crossmember

Y133

Coolant pump switchover valve

Shown on model 177

30

Clip

 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

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-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

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 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

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Information on influencing load ratios when removing major assemblies

AH00.60-P-0001-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

Notes on handling refrigerant R1234yf

AH83.30-P-0003-02A

Notes on safety-relevant components

AH00.00-Z-0019-01A

Notes about Common-Rail components

AH07.16-P-0002-01TX

Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases

AH01.10-P-0001-01A

 

Remove/install

1

Put transmission into neutral position.

2

Secure vehicle against rolling away and release parking brake.

3

Secure vehicle on vehicle lift.

AR00.60-P-1006A



000 588 00 80 00 Vehicle lift

WS00.00-P-0040B

 Vehicle hoist securing tool

*171589013100

 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

4

Remove upper engine cover.



AP01.10-P-2405-01B

 Installation: Only install upper engine cover after the leak test.

5

Disconnect ground line of on-board electrical system battery (G1).

AR54.10-P-0003MFA

6

Remove front module.

AR88.30-P-1064MFA

 Installation: Only install lower engine compartment paneling after leak test.

7

Discharge air conditioning system.

AR83.30-P-1760MFA

8

Drain off coolant.

AR20.00-P-1142MFE

9

Remove the coolant expansion reservoir.

AR20.30-P-4949MFE

10

remove the coolant lines (9, 33) and seal the openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

11

Remove the control unit CDI (N3/9).

AR07.08-P-7009MFE

12

Remove air filter housing.

AR09.10-P-1150MFE

13

Release and disconnect the electrical connector (1).

14

Remove battery carrier.

AR54.10-P-0028MFA

15

Remove cover (2).

16

Remove nut (3) and remove the electrical line from the stud bolt.

 Nut, feed line for glow output stage to prefuse box

*BA15.18-P-1002-01I

17

Release and disconnect the electrical connector for the fan (4).

18

Remove the  AdBlue®  metering valve (Y129) from the catalytic converter unit and engine and set aside.

AR49.20-P-2000MFE

19

Seal the openings on the  AdBlue®  metering valve (Y129) and catalytic converter unit with protective covers.

 Set of protective covers

*001589019100

20

Remove the NOx sensor control unit upstream of the SCR catalytic converter (N37/7) from the bracket and place it on the engine.

AR49.20-P-2063MFE

21

Remove coolant hoses (5, 6, 10) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

22

Remove the refrigerant lines (7) from the condenser and seal the openings with suitable stop plugs.

 Installation: Replace seals.

 Nut, refrigerant line to condenser

*BA83.30-P-1007-01T

 Record plug

*129589009100

23

Remove the nut (8), disconnect the refrigerant line, and seal the openings with suitable stop plugs.

 Installation: Replace seal.

 Nut, refrigerant line connecting point

*BA83.30-P-1002-01T

 Record plug

*129589009100

24

Pull radiator package out of rubber guides and set down on suitable base.

 Installation: Wet rubber guides with lubricant.

 Collect escaping coolant using suitable vessel.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

25

Check rubber guides for damage and wear.

If there are problems,



Replace rubber guides.

 Installation:
Wet rubber guides with lubricant.

Lubricant, rubber assembly 1 l

*BR00.45-Z-1010-06A

26

Remove the fuel hoses (11) from the engine and seal the openings with suitable stop plugs.

 Installation: Replace fuel hoses (11).

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

27

Remove vacuum line (14) from vacuum pump (15) and seal openings with suitable stop plugs.

 Record plug

*129589009100

28

Remove coolant hose (12) from the thermostat housing and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

29

Remove coolant hose (13) from the engine and seal openings with protective covers.

 Hose clamp pliers

*454589003700

 Set of protective caps

*001589009100

30

Release and disconnect the electrical connector (19.1) and unclip the electrical line on the transmission.

 Clip remover

*452589016300

31

Release and disconnect electrical connector (19.2) and unclip electric line at transmission.

 Clip remover

*452589016300

32

Remove the caps (17).

33

Remove nuts (18).

 Nut, alternator/starter wiring harness to busbar

*BA15.18-P-1003-01I

34

Release and disconnect the electrical connectors (21, 22).

35

Unclip the electrical connector (22) from the crossmember (29).

 Clip remover

*452589016300

36

Unclip the electrical line (23) from the crossmember (29).

 Clip remover

*452589016300

If the retaining clip for the electrical line (23) is damaged,



Replacing retaining clip.

37

Remove shift cables from transmission.

AR26.60-P-0635MFA

38

Disconnect hydraulic line of the clutch operation from the clutch slave cylinder and seal openings with suitable stop plugs.

 Record plug

*129589009100

39

Unclip the electrical line (16) from the coolant pump switchover valve (Y133) on the crossmember (29).

 Clip remover

*452589016300

40

Unclip the locks (24) from the crossmember (29).

41

Remove coolant line (25) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

42

Remove the screws (26).

 Bolt, radiator support to mounting support

*BA62.30-P-1004-02O

43

Remove screws (27) and remove connecting carriers (28) together with crossmember (29).

 Aid of helper required.

 Bolt, connecting carrier to front axle carrier/radiator support

*BA62.30-P-1003-02O

44

Remove front axle shafts.

AR33.30-P-0620MFA

45

Remove bottom engine stabilizer mount.

AR22.10-P-1155MFE

46

Remove the clamp (30).

 Clamp, center exhaust system to front exhaust system

*BA49.10-P-1003-02R

47

Attach engine support fixture to the engine transmission unit.

AR01.10-P-0106MFA

48

Remove the screws (32).

 Screw, engine mount to mounting support

*BA22.10-P-1004-03P

49

Remove the screws (31).

 Screw, transmission mount to body/transmission

*BA22.10-P-1010-03P

50

Move out engine with the transmission toward the front out of the vehicle.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully move out engine with the transmission.
Damage and function impairments will otherwise occur.

 Aid of helper required.

 Support fixture

*177589026200

51

Install in the reverse order.

52

Bleed clutch operating system.

AR25.20-P-0070MFA

53

Connect vehicle diagnosis system, read out fault memory, and delete.



AD00.00-P-2000-06MFA



Check

54

Check transmission oil level and correct if necessary.

AR26.00-P-0200MFA

55

Check engine oil level and correct if necessary.



AP18.00-P-1812MFA

 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

56

Perform engine test run and check engine and transmission for proper operation and leak tightness while doing so.

57

Install lower engine compartment lining.

AR61.20-P-1105MFE

 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

58

Install upper engine cover.



AP01.10-P-2405-01B

 Engine wiring harness

Number

Designation

Engine 608

BA15.18-P-1002-01I

Nut, feed line for glow output stage to prefuse box

Nm

8

 Engine wiring harness

Number

Designation

Engine 608

BA15.18-P-1003-01I

Nut, alternator/starter wiring harness to busbar

M8

Nm

16

 Engine mount, engine support (engine side)

Number

Designation

Model 118, 177, 247

BA22.10-P-1004-03P

Screw, engine mount to mounting support

Nm

58

 Engine mount, engine support (engine side)

Number

Designation

Model 118, 177, 247

BA22.10-P-1010-03P

Screw, transmission mount to body/transmission

Nm

106

 Exhaust system

Number

Designation

Model 247 with engine 608

Model 118 with engine 608

BA49.10-P-1003-02R

Clamp, center exhaust system to front exhaust system

Nm

21

21

 Exhaust system

Number

Designation

Model 177 with engine 608

BA49.10-P-1003-02R

Clamp, center exhaust system to front exhaust system

Nm

21

 Frond end with front reinforcement

Number

Designation

Model 118

Model 177

BA62.30-P-1003-02O

Bolt, connecting carrier to front axle carrier/radiator support

M8

Nm

16

16

 Frond end with front reinforcement

Number

Designation

Model 247

BA62.30-P-1003-02O

Bolt, connecting carrier to front axle carrier/radiator support

M8

Nm

16

 Frond end with front reinforcement

Number

Designation

Model 118

Model 177

BA62.30-P-1004-02O

Bolt, radiator support to mounting support

M8

Nm

16

16

 Frond end with front reinforcement

Number

Designation

Model 247

BA62.30-P-1004-02O

Bolt, radiator support to mounting support

M8

Nm

16

 Air conditioning

Number

Designation

Model 118

Model 177

BA83.30-P-1002-01T

Nut, refrigerant line connecting point

M6

Nm

12

12

M8

Nm

20

20

 Air conditioning

Number

Designation

Model 247

BA83.30-P-1002-01T

Nut, refrigerant line connecting point

M6

Nm

12

M8

Nm

20

 Air conditioning

Number

Designation

Model 118

Model 177

BA83.30-P-1007-01T

Nut, refrigerant line to condenser

M6

Nm

12

12

 Air conditioning

Number

Designation

Model 247

BA83.30-P-1007-01T

Nut, refrigerant line to condenser

M6

Nm

12

Repair materials

Number

Designation

Order number

BR00.45-Z-1010-06A

Lubricant, rubber assembly 1 l

A 000 989 03 67