Remove/install engine with transmission

AR01.10-P-2401MNF

Remove/install engine with transmission

28.08.2019

Engine

176 in model 463

up to model year 2019

Modification notes

13.07.2017

Operation steps revised.

Operation step 1 to operation step 56.

1

Air cleaner housing

7

Separating points

8

Purge lines

18

Coolant hose

31

Vacuum line

32

Fuel feed hose

33

Fluid reservoir

34

Refrigerant line

2

Intake air ducts

3

Heat shield

4

Bolts

5

Heat shield

6

Bolts

9

Purge valve

22

Refrigerant line

23

Screw

24

Line

25

Hose

26

Power steering refrigerant reservoir

27

Oil line

28

Oil line

10

Coolant hose

11

Coolant hoses

12

Coolant lines

13

Coolant hose

14

Coolant hose

15

Separation point

16

Coolant hose

17

Coolant hose

19

Vent hose

20

Separation point

21

Oil lines

35

Coolant hose

29

Bolts

30

Nuts

 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 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 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

 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 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

 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

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

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

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

AH01.10-P-0001-01A

 

Remove/install

1

Secure vehicle against rolling

2

Shift transmission to neutral and release parking brake

3

Turn front wheels to straight-ahead position and fix steering wheel in place with holding device


Do not turn steering wheel with steering coupling removed.
Otherwise the clock spring contact will be destroyed.

 Retainer device

*129589012100

4

Secure vehicle on vehicle lift

Engine 176 in model 463
up to model year 2019

AR00.60-P-1000G

5

Disconnect ground cable at battery

Engine 176 in model 463 (except 463.23)
as of model year 2013 up to model year 2019

AR54.10-P-0003GW

6

Drain air conditioning system

Engine 176 in model 463
as of model year 2013 up to model year 2019

AR83.30-P-1760GW

7

Remove left and right air filter housing (1)

AR09.10-P-1150MNA

8

Replace left and right oxygen sensor upstream of CAT

AR07.04-P-0021MNF

9

Remove intake air ducts (2)

10

Remove heat shield (3) on left and right ATL

AR09.40-P-6026MNA

11

Remove screws (4) and remove heat shield (5)

 Bolt, rear heat shield to bracket

*BA09.40-P-1008-01ZA

 Bolt, upper heat shield to bracket/side heat shield

*BA09.40-P-1006-01ZA

12

Remove screws (6) and remove bracket of the catalytic converters

 Screw/bolt, catalytic converter bracket to bracket

*BA49.10-P-1004-02F

 Bolt, bracket to catalytic converter

*BA49.10-P-1005-02F

13

Remove left and right catalytic converter from the left and right exhaust gas turbocharger

AR09.40-P-6026MNA

14

Remover whole radiator package

AR20.20-P-3865MNF

 The radiator package consists of the cooler, the cooler for the low-temperature water circuit, and the condenser of the air conditioning.

15

Disconnect purge lines (8) from the separating points (7) and seal exposed connections with suitable stop plugs

 Record plug

*129589009100

16

Unclip purge valve (9) and lay down to side with hoses connected

17

Remove oil line of the power steering

Engine 176 in model 463 (except 463.222/323)
as of model year 2013 up to model year 2019

AR46.25-P-3010GW

18

Remove coolant hose (10) from right charge air cooler

 Hose clamp pliers

*003589033700

19

Remove coolant hoses (11) from the coolant lines (12)

 Hose clamp pliers

*003589033700

20

Remove coolant hose (13) from the bottom low-temperature circuit expansion reservoir

AR20.20-P-7441-01RQ

21

Remove coolant hose (14) from the separating point (15)

AR20.20-P-7441-01RQ

22

Unclip coolant hose (14) at coolant hose (16)

23

Remove coolant hoses (16, 35) from the coolant pump

AR20.20-P-7441-01RQ

24

Unclip coolant hose (16, 35) at cover panel on alternator

25

Remove coolant hose (17) from thermostat housing

AR20.20-P-7441-01RQ

26

Remove coolant hose (18) from firewall

AR20.20-P-7441-01RQ

27

Remove vent hose (19) from the separating point (20)

AR20.20-P-7441-01RQ

28

Remove oil lines (21) from the crankcase, capture escaping engine oil in a suitable container, and seal openings using suitable stop plugs

 Installation: Install new sealing rings.

 Bolt, oil line to engine

*BA18.30-P-1009-01N

 Record plug

*129589009100

29

Remove refrigerant line (22) from the refrigerant compressor, place to one side, and seal openings with suitable stop plugs

 Installation:
Wet thread and seal with compressor oil.
Otherwise refrigerant may escape.

 Installation: Replace seal.

 Bolt, refrigerant line to refrigerant compressor

*BA83.55-P-1003-02A

 Record plug

*129589009100

30

Remove bolt (23)

 Bolt, refrigerant compressor to bracket for belt tensioner/ oil pan/ crankcase

*BA83.55-P-1005-02A

31

Remove line (24) from the power-steering pump, seal openings with suitable stop plugs, and place line (24) to one side

AR46.30-P-0500GWA

 Record plug

*129589009100

32

Remove hose (25) from the power steering refrigerant reservoir (26) and seal openings using suitable stop plugs

 Record plug

*129589009100

33

Disconnect engine wiring harness for removal of engine

AR01.00-P-2410-03MNF

 Nut, electrical line to battery compartment prefuse box

*BA54.15-P-1001-02A

34

Unclip electrical line of left and right oxygen sensor downstream of CAT on side heat shield of the left or right ATL

35

Unclip electrical line of left and right oxygen sensor downstream of CAT on side heat shield of the left or right ATL

36

Remove ground line at transmission

Engine 176 in model 463 with transmission 722.9
up to model year 2019

 Bolt, ground line to transmission housing

*BA27.40-P-1008-01E

37

Remove bracket of the oil line (27) from the transmission

Engine 176 in model 463 with transmission 722.9
up to model year 2019

AR27.55-P-0600MNF

38

Remove oil lines (27, 28) from the transmission and place to one side

Engine 176 in model 463 with transmission 722.9
up to model year 2019

AR27.55-P-0600MNF

39

Remove propeller shaft from the front flex disk and secure against falling down

AR41.10-P-0050GW

40

Remove rear engine mount from the rear engine crossmember

AR22.10-P-1160GW

41

Remove screws (29)

 Nut/bolt, front engine mount to bracket

*BA22.10-P-1002-01X

42

Unscrew nuts (30)

 Nut, single-tube engine vibration damper to frame/engine support

*BA22.10-P-1004-01X

43

Remove vacuum line (31) from firewall

AR20.20-P-7441-01RQ

44

Relieve fuel pressure at diagnostic socket

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

45

Remove fuel feed hose (32) from the service connection of the low-pressure line and seal openings with suitable stop plugs

 Union nut, fuel hose to diagnostic socket/fuel line

*BA07.03-P-1006-01H

 Record plug

*129589009100

46

Remove right front fender liner

47

Open screw clamp on fluid reservoir (33)

48

Release and disconnect electrical connection on fluid reservoir (33)

49

Remove brackets from the refrigerant line (34)

50

Place refrigerant reservoir (33) to one side with connected lines

51

Attach engine lifting lug to the cylinder heads

 Use screw/bolts M7x1 with a length of 65 mm.

 M71

*BA00.10-P-1003-04A

 Lifting eye

*177589006200

52

Attach load tilter and engine crane to the engine and lift engine somewhat



000 588 00 62 00 Load tilter

WS01.00-P-0102B

 Commercially available devices/tools
Engine crane

53

Lift out engine with transmission toward front



000 588 00 62 00 Load tilter

WS01.00-P-0102B


Lift out and lift in engine carefully for a tilt of a maximum of 30°.
Lines and components can otherwise be damaged due to pinching and impacts.

 Aid of helper required.

 Commercially available devices/tools
Engine crane

54

Install in the reverse order



Check

55

Check engine oil level; correct if necessary



AP18.00-P-0101GE

 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 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 an engine test run, check engine and transmission for proper operation and leaktightness while doing so

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1003-04A

M71

Nm

15

22

 Injection nozzles, injection valves, lines

Number

Designation

Engine 176

BA07.03-P-1005-01H

Dust protection cap to service connection

Nm

1

 Injection nozzles, injection valves, lines

Number

Designation

Engine 176

BA07.03-P-1006-01H

Union nut, fuel hose to diagnostic socket/fuel line

Nm

24

 Turbocharger

Number

Designation

Engine 176

BA09.40-P-1006-01ZA

Bolt, upper heat shield to bracket/side heat shield

Nm

9

 Turbocharger

Number

Designation

Engine 176

BA09.40-P-1008-01ZA

Bolt, rear heat shield to bracket

Nm

9

 Oil cooling

Number

Designation

Engine 176 except in model 463,
engine 176 in model 463 up to model year 2019

BA18.30-P-1009-01N

Bolt, oil line to engine

Nm

8

 Engine mounts, engine supports

Number

Designation

Engine 176 in model 463
up to model year 2019
Engine 279 in model 463

BA22.10-P-1002-01X

Nut/bolt, front engine mount to bracket

M10

Nm

70

 Engine mounts, engine supports

Number

Designation

Engine 176 in model 463
up to model year 2019
Engine 279 in model 463

BA22.10-P-1004-01X

Nut, single-tube engine vibration damper to frame/engine support

M6

Nm

5

 Housing

Number

Designation

Transmission 722.9 in model 463

BA27.40-P-1008-01E

Bolt, ground line to transmission housing

Nm

9

 Exhaust system

Number

Designation

Engine 176 in model 463
up to model year 2019

BA49.10-P-1004-02F

Screw/bolt, catalytic converter bracket to bracket

Nm

25

 Exhaust system

Number

Designation

Engine 176 in model 463
up to model year 2019

BA49.10-P-1005-02F

Bolt, bracket to catalytic converter

Nm

20

 Fuse and relay module

Number

Designation

Model 463
up to model year 2019

BA54.15-P-1001-02A

Nut, electrical line to battery compartment prefuse box

M6

Nm

8

M8

Nm

16

 Refrigerant compressor

Number

Designation

Engine 176

BA83.55-P-1003-02A

Bolt, refrigerant line to refrigerant compressor

Nm

20

 Refrigerant compressor

Number

Designation

Engine 176

BA83.55-P-1005-02A

Bolt, refrigerant compressor to bracket for belt tensioner/ oil pan/ crankcase

Nm

20