Remove/install engine with transmission

AR01.10-P-2401OLD

08.01.2020

Engine	651 in model 205 with transmission 716
	except code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine	651 in model 205 with transmission 722 (except 722.96), 724
Engine	651 in model 205 with transmission 725
	except code M005 (Vehicles with 4MATIC/all-wheel drive)

Modification notes

21.09.2017

Operation steps revised

Operation steps 1 to 51

P01.00-3510-09

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

1	Vacuum line separating point	4	Bracket
2	Rear right engine suspension lug	5	Electrical wiring harness
3	Coolant hose

P01.10-3229-08

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

6	Charge air pipe	11	Charge air cooler
7	Low-temperature circuit coolant line	12	Coolant hose
8	Bracket	13	Coolant hose
9	Screw	14	Refrigerant high-pressure line
10	Vent line	15	Refrigerant low-pressure line

Shown: Engine 651 in model 205 except code ME04 (mild hybrid drive)

16	Automatic transmission oil cooler
17	Low-temperature circuit coolant line
18	Coolant hose
19	Coolant hose

P01.00-3511-06

Shown: Engine 651 in model 205 with transmission 722.9 except code ME04 (mild hybrid drive)

20	Reinforcement
21	Ground cable
22	Fuel hoses

P01.10-3228-11

Shown: Engine 651 in model 205 with transmission 724.2 with code ME04 (mild hybrid drive)

23	High voltage electrical line

P54.10-4154-12

 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 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
 Danger	Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)	Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.	AS00.00-Z-0035-01A
 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
 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
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
Topical note	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
Topical note	General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system		AH00.00-Z-0300-01A
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	Notes on engine oil and filter changes		AH18.00-P-0104-01A
Topical note	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
Topical note	Notes on battery		AH54.10-P-0001-01A
	Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases		AH01.10-P-0001-01A
	Notes about Common-Rail components		AH07.16-P-0002-01TX
	Notes on automatic transmission	Engine 651 in model 205 with transmission 722 (except 722.96), 724 Engine 651 in model 205 with transmission 725 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AH27.19-P-0001-01NKB
 	Remove/install
1	Secure vehicle to prevent it moving away.
2	Move transmission to neutral position and release the parking brake.
3	Deactivate easy entry and exit feature.	Engine 651 in model 205 with transmission 716 with code 275 (Driver's seat, electrically adjustable with memory function) except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 205 with transmission 722 (except 722.96), 724 with code 275 (Driver's seat, electrically adjustable with memory function)
		 Deactivation takes place over the "Vehicle settings" menu and submenu "Easy entry and exit feature" in multifunction display, see vehicle operator's manual.
4	Turn steering wheel to center position (front wheels in straight-ahead position) and fix in place using holding device.		AR46.20-P-0600-01LW
		 Retainer device	*129589012100
5	Perform power disconnect of high-voltage on-board electrical system.	Engine 651 in model 205.012/212 with code ME04 (Mild hybrid drive)
			AR54.10-P-1150LW
6	Discharge air conditioning system.		AR83.30-P-1760LW
7	Disconnect ground line from battery.		AR54.10-P-0003LW
8	Remove lower engine compartment linings.		AR61.20-P-1105LW
		 Installation: Only install lower engine compartment lining after leak test.
9	Remove drain screw at oil pan, drain engine oil, and catch in suitable container.	 Installation: Replace sealing ring.
		 Drain screw to oil pan	*BA01.45-P-1003-01S
10	Drain coolant at radiator.		AR20.00-P-1142LW
11	Drain coolant of low-temperature circuit.		AR09.41-P-6834LW
12	Remove upper engine cover.	 Installation: Only install upper engine cover after the leak test.
13	Disconnect vacuum line of the vacuum pump at vacuum line connecting point (1).
14	Unhook vacuum line at bracket (arrow) and place to one side.
15	Remove engine air intake duct downstream of air filter.		AR09.10-P-8130OLD
16	Remove charge air pipe (6) upstream of charge air cooler (11).		AR09.41-P-8623OLD
17	Remove bolt (9) and remove low-temperature circuit coolant line (7) from bracket (8).	 Bolt, low-temperature circuit coolant line to low-temperature circuit coolant line bracket	*BA09.41-P-1002-03C
18	Remove bleed line (10) at low-temperature circuit coolant expansion reservoir.		AR20.20-P-7441-01RQ
19	Remove coolant hose (12) from the thermostat housing.		AR20.20-P-7441-01RQ
20	Remove coolant hose (13).		AR20.20-P-7441-01RQ
21	Remove low-temperature circuit coolant line (7) from charge air cooler (11), place to one side and fix in place.		AR20.20-P-7441-01RQ
22	Remove coolant hose (18) at fitting.		AR20.20-P-7441-01RQ
23	Remove coolant hose (19).		AR20.20-P-7441-01RQ
24	Remove refrigerant high-pressure line (14) from refrigerant compressor, place to one side and seal openings using suitable stop plugs.
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Installation: Replace sealing ring and moisten sealing ring and thread with compressor oil.
		 Refrigerant line to refrigerant compressor	*BA83.55-P-1003-01W
		 Record plug	*129589009100
25	Remove refrigerant low-pressure line (15) and seal openings with suitable stop plugs.
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Installation: Replace sealing ring and moisten sealing ring and thread with compressor oil.
		 Refrigerant line to refrigerant compressor	*BA83.55-P-1003-01W
		 Record plug	*129589009100
26	Disconnect engine wiring harness for removal of engine and place to one side.		AR15.18-P-1000-03OLD
		 Nut, positive line to engine compartment prefuse box	*BA54.15-P-1003-01K
27	Remove bracket (4) together with electrical wiring harness (5) from rear right engine lifting lug (2) and place to one side.
28	Remove coolant hose (3) from connection fitting for coolant return line at cylinder head and place to one side.	 Hose clamp pliers	*003589033700
29	Remove catalytic converter DPF unit.		AR49.10-P-5501LWB
30	Remove fan unit.		AR20.40-P-5050LWB
31	Fasten automatic transmission oil cooler (16) to engine free of tension.	Engine 651 in model 205 with transmission 722 (except 722.96), 724
32	Mount protective plate on cooler.
			WF58.50-P-0110-01A
33	Disconnect steering coupling from steering shaft.	Engine 651 in model 205 with transmission 716 except code 700 (Technology Local Content China) except code M005 (Vehicles with 4MATIC/all-wheel drive) Engine 651 in model 205 with transmission 722 (except 722.96), 724 except code 700 (Technology Local Content China) Engine 651 in model 205.0/2/3/4 with transmission 725 except code 700 (Technology Local Content China) except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR46.10-P-8000-01LW
		 Do not turn steering wheel with steering coupling removed. Otherwise, the clock spring contact is damaged.
		 Engine mount wrench set	*001589011600
34	Remove low-temperature circuit coolant line (17) from automatic transmission oil cooler (16).	Engine 651 with transmission 722 (except 722.96)	AR20.20-P-7441-01RQ
35	Disconnect ground line (21) from body.
36	Remove reinforcement (20).	 Bolt, front reinforcement/bracket to frame floor assembly	*BA61.10-P-1002-01L
37	Detach propeller shaft from output flange on transmission.		AR41.10-P-0050LW
		 Mark installation position of propeller shaft in relation to output flange on transmission.
38	Detach center shifter console and shift rod from transmission.	Engine 651 in model 205 with transmission 716 except code M005 (Vehicles with 4MATIC/all-wheel drive)
	000 588 10 62 00 Support plate		WS26.00-P-3309B
	000 588 11 62 00 Major assembly mount		WS01.00-P-0092B
			AR26.60-P-0600-02LW
		Long-life grease	*BR00.45-Z-1001-06A
39	Disconnect electrical connection for transmission neutral position sensor (B79/2) on the right side on the transmission.	Engine 651 in model 205 with transmission 716 except code M005 (Vehicles with 4MATIC/all-wheel drive)
40	Remove hydraulic hose at clutch slave cylinder and seal openings with suitable stop plugs.	Engine 651 in model 205 with transmission 716 except code M005 (Vehicles with 4MATIC/all-wheel drive)	AR25.20-P-0150LW
		 Installation: Replace sealing ring.
		 Record plug	*129589009100
41	Disconnect fuel hoses (22) at fuel lines and seal connections using suitable stop plugs.	 Pliers for click clamps	*171589003700
		 Clamp	*000589403700
		 Record plug	*129589009100
42	Remove rear engine mounts.		AR22.10-P-1160LWB
43	Install rear engine carrier.		AR22.10-P-4360LWB
44	Lower engine with transmission onto the rear engine support.	 Engine 651 in model 205 with transmission 724.2 Carefully lower engine with transmission. Otherwise the high voltage electrical lines (23) may be damaged.
45	Release and disconnect high voltage electrical lines (23) on high-voltage battery module and close off high-voltage plug with protective covers.	Engine 651 in model 205.012/212 with transmission 724.2
			AR54.10-P-1400LW
		 Set of protective covers	*001589039100
46	Remove high voltage electrical lines (23) through the transmission tunnel upwards in the engine compartment and lay on the right wheel arch.	Engine 651 in model 205 with transmission 724
47	Hook load tilter and boom crane into rear right engine lifting lug (2), left engine lifting lug and front center engine lifting lug, and raise the engine.
	000 588 00 62 00 Load tilter		WS01.00-P-0102B
		 Do not subject the engine mounts to tension. The engine mount can get damaged otherwise.
		 Commercially available devices/tools Boom crane
48	Remove screw/bolts of front engine mount to engine supports.		AR22.10-P-1260LWB
49	Lift out engine together with transmission.
	000 588 00 62 00 Load tilter		WS01.00-P-0102B
		 Do not jam any component parts when lifting the engine with transmission in and out. Otherwise, surrounding components may be damaged.
		 Commercially available devices/tools Boom crane
		 Two helpers required.
50	Install in the reverse order.
	Check
51	Check engine oil level and correct if necessary.
			AP18.00-P-1811MP
52	Bleed clutch operating system.	Engine 651 in model 205 with transmission 716.7 except code M005 (Vehicles with 4MATIC/all-wheel drive)
			AR25.20-P-0070LW
 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
53	Perform engine test run; while doing so, check engine and transmission for proper operation and leak tightness.

 Oil pan

Number	Designation			Engine 651
BA01.45-P-1003-01S	Drain screw to oil pan	Metal	Nm	30
		Plastic	Nm	4

 Charge air cooler

Number	Designation		Engine 651 in model 205
BA09.41-P-1002-03C	Bolt, low-temperature circuit coolant line to low-temperature circuit coolant line bracket	Nm	8

 Fuse and relay box

Number	Designation			Model 205
BA54.15-P-1003-01K	Nut, positive line to engine compartment prefuse box	M6	Nm	8
		M8	Nm	16

 Frame floor assembly

Number	Designation			Model 205
BA61.10-P-1002-01L	Bolt, front reinforcement/bracket to frame floor assembly	M10x20	Nm	-
		M10x28	Nm	30

 Refrigerant compressor

Number	Designation		Engine 651 in model 117, 156, 166, 172, 176, 205, 212, 218, 221, 222, 246, 253
BA83.55-P-1003-01W	Refrigerant line to refrigerant compressor	Nm	20