M177 in model W205. Remove/install Downpipes

Transcription

1 Remove/install Downpipes M177 in model W205 1 Heat shield 2 Screw/bolts 3 Screw/bolts 6 Electrical line 7 Electrical line 8 Electrical line 9 Electrical line 10 Heat shield 17 Screw/bolts 18 Bracket 31 Cover 4 Left oxygen sensor 5 Right oxygen sensor 11 Bracket 12 Clamp 13 Clamp 14 Left catalytic converter 15 Right catalytic converter 16 Screw/bolts 19 Electrical line

2 Transmission Removal in model W205 with engine M177 1 Transmission 3 Ground cable 9 Heat shield 10 Bracket 11 Electrical line 1 Transmission 6 Start up clutch 6a Bearing journal Remove/install 1 Position transmission (1) to position "N" 2 Release parking brake 3 Secure vehicle on vehicle lift 4 Detach ground line from battery 5 Remove bottom engine compartment paneling 6 Remove bracket (10)

3 7 Disconnect electrical connection from electrical auxiliary oil pump and unclip electrical line from transmission (1) Installation: Make sure that the electrical line is routed and secured correctly. 8 Release and detach electrical connection from intelligent servo module for DIRECT SELECT, and expose electrical line Installation: Make sure that the electrical line is routed and secured correctly. 9 Remove heat shield (9) over electrical connection of electric controller unit 10 Disconnect electrical connection of electric controller unit from transmission 11 Disconnect electrical connection from exhaust system and unclip electrical line (11) up to transmission (1) 12 Detach ground line (3) from transmission (1) 13 Detach oil lines from transmission (1) and oil pan and place to one side 14 Support and lash down transmission (1) 15 Remove rear engine support Notes on bolted connections with self tapping screws Never use impact wrench or compressed air tools for screwing in or unscrewing the bolts! Otherwise the threads can get damaged. 16 Mark front flex disk relative to output flange of the transmission (1) using color markings and detach Drift for releasing the fitting sleeves in the flexible couplings Flex disk or joint flange at transmission/ rear axle differential or propeller shaft 17 Detach start-up clutch (6) from drive plate Installation: Replace the screws/bolts of and pry off from drive plate uniformly using the start-up clutch (6). long wedge Bolt, start up clutch to driver Socket wrench bit Long wedge 18 Remove screws/bolts and take out transmission (1) in a downward direction Secure the start-up clutch (6) to prevent it from falling down. Otherwise damage will occur. Installation: Align the holes of the start-up clutch (6) with the threaded unions in the drive plate. Bolt, automatic transmission to engine 19 Remove start-up clutch (6) with grab handles If necessary Installation: Apply a little multi-purpose paste to journal (6a). Multi-purpose paste Installed height of start up clutch Handles Parallel rest 20 Remove corrosion from crankshaft Multi-purpose paste Assembly cleaner 21 Check threaded unions in drive plate If threaded unions are damaged or loosened: Replace drive plate. 22 Install in the reverse order 23 Check transmission oil level and correct if necessary 24 Read out fault memory using the diagnostic system and delete if necessary 25 Perform transmission adaptation using After replacement or repair of transmission (1) diagnostic system

4 26 Reset data on service life of torque converter After replacement of start-up clutch (6) lockup clutch using diagnostic system Danger! Risk of accident from vehicle starting off by Secure vehicle to prevent it from starting off by itself when engine running. Risk of injury itself. Wear closed and snug-fitting work (bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 27 Perform engine test run and check transmission (1) for proper operation and leaktightness Test values for start up clutch Number Designation Transmission Installed height of start up clutch Distance, bolt flange mm 9,5 to transmission housing flange Housing Number Designation Transmission Bolt, automatic transmission to engine M10 40 Nm 38 M10 45 Nm 38 M10 90 Nm 38 M12 Nm Start up clutch Number Designation Transmission Bolt, start up clutch to driver Stage 1 Nm 4 Stage 2 Nm 30 Stage 3 90 Propeller shaft Number Designation Model 205 Flex disk or joint flange at Self-locking nut Nm 68 transmission/rear axle differential or propeller shaft Direct threaded Stage 1 Nm 60 connection Stage 2 90

5 2 Disconnect electrical connection for left oxygen sensor (4) or right oxygen sensor (5) downstream of catalytic converter 3 Detach left and right CAT (14, 15) at center exhaust system 4 Remove left and right air filter housing 5 Remove cover (31) Installation: Check for correct seating of the cover (31). 6 Remove screw/bolts (2) and remove heat Bolt, upper heat shield to bracket/side shield (1) upwards heat shield 7 Unclip electrical lines (6, 7, 8, 9) from heat shield (10) 8 Remove screw/bolts (3) and remove heat Bolt, rear heat shield to bracket shield (10) upwards Bolt, upper heat shield to bracket/side heat shield 9 Remove left oxygen sensor (4) and right oxygen sensor (5) 10 Remove clamp (12) or clamp (13) Installation: If one one-piece clamp (12) or clamp (13) it installed, this must be replaced. For a two-piece clamp (12) or clamp (13) replace the bolt and nuts. Clamp, front exhaust system to turbocharger For installation of the clamp (12) or clamp (13): Align clamp (12) or clamp (13) between the ATL and catalytic converter. Clamp, front exhaust system to turbocharger Caulking bolt 11 Remove screw/bolts (17) from bracket (18) Bolt, butterfly bracket to catalytic converter 12 Remove screw/bolts (16) from bracket (11) Bolt, rear heat shield bracket to crankcase 13 Remove bracket (18) and bracket (11) upwards 14.1 Detach steering coupling from rack-and-pinion For removal the left CAT (14) steering 14.2 Detach heat shield over electrical lines (19) For removal the right CAT (15) 15 Detach electrical lines (19) and place to one For removal the right CAT (15) side Nut, positive line to busbar on firewall 16 Remove left CAT (14) or right CAT (15) downwards 17 Remove left oxygen sensor (4) and right When replacing the left or right CAT (14, 15) oxygen sensor (5) Clean 18 Remove combustion and corrosion residue at separating points 19 Install in the reverse order Check 20 Check installation position and unobstructed movement of all parts of the exhaust system Danger! Risk of accident from vehicle starting off by Secure vehicle to prevent it from starting off by itself when engine running. Risk of injury itself. Wear closed and snug-fitting work (bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 21 Perform an engine test run and check exhaust system for leaktightness

6 Turbocharger Number Designation Engine 177 Bolt, rear heat shield bracket to crankcase Nm 9 Turbocharger Number Designation Engine 177 Bolt, upper heat shield to bracket/side heat shield Nm 9 Turbocharger Number Designation Engine 177 Bolt, rear heat shield to bracket Nm 9 Exhaust system Number Designation Engine in model 205 Clamp, front exhaust system to turbocharger Nm 20 Exhaust system Number Designation Engine in model 205 Bolt, butterfly bracket to catalytic converter Nm 20 Wiring harness Number Designation Model 205 Nut, positive line to busbar on firewall M6 Nm 8 M8 Nm 16