Removal and installation of the power unit (Mercedes-Benz Vito W639)

1. Disconnect the negative battery cable. To do this, follow these steps: (pp. 1.1-1.6),

1.1 Remove the cover (1) on the driver's seat base.

1.2. Disconnect the battery ventilation hose (3).

1.3. Remove the battery bracket (4).

1.4. Disconnect the negative battery cable (8) from the battery (7).





1.5. Perform installation in reverse order.

1.6 Perform initial programming of the control system.

2. Remove the front panel (1). To do this, follow the steps (pl. 2.1-2.22).













2.1 Remove the air filter housing.

2.2. Remove oil from the power steering system supply tank (hereinafter referred to as GUR), disconnecting the return oil line (1).

2.3. Disconnect the oil lines (2) from the power steering system oil cooler. Install plugs in the holes of the disconnected hoses.

2.4. Disconnect the cooling system hose to remove the front block.

2.5. Unfasten the wiring harness (3) fastening to the front block.



2.6. Disconnect the quick release connector (4) from the headlight washer and plug the connector.

2.7. Disconnect the hood opening cable (5).

2.8. Disconnect the electrical wires from the top of the front unit.

2.9. Remove the refrigerant from the air conditioning system.

2.10. Unscrew the nut (8) from the high pressure line.

2.11. Remove the expansion clamps (9).

2.12. Disconnect the front protective pan of the engine compartment.

2.13. Remove the charge air intercooler (intercoupler) with air ducts (10).

2.14. Disconnect the wiring harnesses from the bottom of the front panel.

2.15. Disconnect the supply tube (11) and return tube (12).

2.16. Unscrew the screws (13).

2.17. Unscrew the screws (14).

2.10. Unscrew the screws (15).

2.19. Install the mounting fixture on the front panel.

2.20. Unscrew the pints (16).

2.21 Remove the front panel.

2.22. Install the front panel in the reverse order.

When installing, please follow these steps:.

• Fill the power steering system with oil and remove air from the system.
• Check and adjust the oil level in the automatic transmission.
• Adjust the position of the headlights.
• Check that the headlight washer is functioning properly.
• Check the correct operation of the hood lock,

3. Remove the engine compartment protective tray. To do this, follow these steps: (pp. 3.1-3.2).

3.1. Remove the front section (1) of the engine compartment protective tray as follows.

3.1.1. Unscrew the screws (3) (for vehicles with a serial number in the VIN code up to 243 776) or open the locks (3) (for cars with a serial number in the VIN code from 243 777).



3.1.2. Remove the front part (1) of the engine compartment protective tray.

3.1.3. Perform installation in reverse order.

3.2. Remove the rear section (2) of the engine compartment protective tray.

3.2.1. Unscrew the screws (4) or open the locks (similar to p. 3.1.1).

3 2.3. Unscrew the nuts (5).

3 2.4 Remove the rear section (2) of the engine compartment protective tray.

3.2.5. Perform installation in reverse order.

4 Disconnect the electrical connectors and hoses as follows: (pl. 4.1-4.35),

4.1 Remove the cover (1),

4.2. Disconnect the electrical connectors on the injection control unit (6).

4.3. Disconnect the electrical connector (2).

4.4 Disconnect the electrical connectors (3)

4.5. Disconnect the engine wiring harness (4) fasteners and move the harness to the side.

4.6. Disconnect the positive terminal (5) by removing the protective cap and unscrewing the nut

4.7. Disconnect the electrical connector (7) from the output stage of the pre-heating control unit (8).







4.9. Cut off the plastic ties (10).



4.10. By repeatedly pressing the brake pedal, "use up" the vacuum in the vacuum system.

4.11. Disconnect the vacuum hose (11) from the brake booster (12).



4.12. Remove the vacuum tubes (13).



4.13. Remove the front fuel filter bracket screws (only for engines 646.980/981).



4.14. Remove the fuel return hoses (14) (only for engines 646.980/981).

4.15. For other engines - remove the fuel lines (14).



4.16. Disconnect the hose (15) from the thermostat housing (I6).



4.17. Unscrew the screw (18).

4.18. Disconnect the compressor hose (17).

4.19. Plug the connections.

(paragraphs 4.17-4.19 only for vehicles with equipment codes HH9 (adjustable air conditioner) and HH4 (automatic air conditioner).





4.20. Unscrew the connection of the power steering pressure hose (19) from the power steering pump (20).





4.21. Loosen the clamps (21) (drawing VN 2.019).

4.22. Remove the coolant hoses (22).

4.23. Loosen the clamp (23)

4.24. Remove the hose (24).

4.25. Disconnect the hoses (25) (arrow).

(pp. 4.21 -4.25 - for vehicles with serial numbers up to 113950).

4.26. Unscrew the screw (26) (drawing VN 2.020).

4.27. Disconnect the compressor tube (27),

4.28. Plug the pipes.

(paragraphs 4.26, 4.28 only for vehicles with equipment codes HZ7 (adjustable air conditioning (Tempmatik) in the passenger compartment).



4.29. Disconnect the clutch drive hose (28) from the manual transmission.

4.30. Plug the hose.



4.31. Disconnect the ground wire (29) from the power unit by unscrewing the screw (30).



4.32. Disconnect the electrical connector (31) from the manual transmission.





4.33. Disconnect the wire (32) from the generator (33) (drawing VN 2.024).

4.34. Make the connection in reverse order.

4.35. After connecting large cross-section wires, check the reliability of their fastening.



5. Disconnect the primary catalytic converter from the turbocharger flange by following these steps: (pp. 5.1-5.6).

5.1. Disconnect the electrical connector (3) of the oxygen sensor (2) (drawing VN 2.025).

5.2. Remove the catalytic converter 0G (6) (drawing VN 2.027).







5.3. Remove the diesel particulate filter (6) (drawing VN 2.028).

5.4 Remove the exhaust pipe bracket.

5.4.1. Move the clamp (3) to the side (drawing VN 2.025).

5.4.2. Remove the clamp (5) (drawing VN 2.025).

5.5 Remove the primary catalytic converter.

5.6. Perform installation in reverse order.

Installation Notes

- Check the correct installation of the exhaust system components and the absence of contamination that would impede the passage of exhaust gases.

- Check the exhaust system for exhaust leaks while the engine is running.

6. Install the gearbox support device. To do this, follow these steps: (pp. 6.1 -6.6).

6.1. Install the device (1) in place and secure it with the bolt (2) (drawing VN 2.029).

6.2. Install the caliper (3) so that it touches the gearbox and secure it with nuts (5).

6.3. Remove the device (1) in the reverse order.

The actions described in paragraphs. 6.4-6.6, apply only to vehicles equipped with permanent all-wheel drive (equipment code ZG2).

6.4 Install the support spacer (4).

6.5. Move the spacer to the gearbox so that the spacer touches the housing, and secure it with nuts (5).

6.6. Remove the spacer (4) in the reverse order.



7. Remove the propeller shaft by following these steps:.

7.1.1. Disconnect the front section of the propeller shaft from the transfer case (2) (only for vehicles with all-wheel drive(equipment code ZG2).

7.1.2. Disconnect the front section of the propeller shaft (1) from the gearbox (only for vehicles without all-wheel drive).

7.2. Disconnect the rear section of the propeller shaft (1) from the rear drive final drive (3).

7.3. Remove the front section propeller shaft hanger bearing (4).

7.4. Remove the suspension bearing (5) of the rear section of the propeller shaft.

Please note that the spacers for vehicles with and without all-wheel drive are different.

7.5 Remove the propeller shaft (1). To do this, remove the safety bracket (b).

7.6 Check the cardan joints for wear.

7.6.1 Apply extended life grease during assembly (MV long-term grease) on the splined surfaces of the cardan shafts.

7.6.2. Connect the front and rear sections of the propeller shaft.

Attention: the marks on the connected sections of the drive shafts must be positioned as shown in the figure VN 2.031.

8. Remove the front axle drive shaft.

8.1. Disconnect the drive shaft (1) from the transfer case, having first marked the relative positions of the flange and the joint.

8.2. Disconnect the drive shaft (1) from the front axle final drive.

8.3. Perform installation in reverse order 9. Remove the cross beam.

10. Disconnect the manual (automatic) transmission control cables.



11. Place the vehicle on a lifting platform.

12. Remove the oil separator.



13. Remove the power unit by following these steps: (pp. 13.1-13.9).

13.1 Remove the right engine mount bolt.

13.2. Secure the hood in the open position using the support (1) with the lock (2) (drawing VN 2,036).

13.3. Unscrew the nuts (3) and remove the bracket (4) (drawing VN 2.037),

13.4. Install the crossbar (5) with the attached bar (6) and secure it at the points (7).

13.5 Install the C-bracket.

13.6. Adjust the position of the center of mass of the power unit using the nut (8).



13.7. Unscrew the left engine mount screw (9).

13.8. Lift the power unit and remove it from the engine compartment, adjusting the position of the center of gravity using the nut (9), if necessary.

13.9. Install the power unit in the reverse order.

14. Perform installation in reverse order.

15. Remove air from the hydraulic clutch drive (for manual transmission 716.6), for which follow these steps (pp. 15.1-15.5).

15.1. Remove the plug (1) on the clutch housing. (drawing VN 2.038)



15.2. Remove the cap on the coaxial clutch slave cylinder.

15.3. Unscrew the bleed valve using a socket wrench (2).

15.4 Remove air from the hydraulic system.

15.5. Screw in the bleed valve, close it with the cap and install the plug (1).



16. Check the ease of movement of the gearbox control cables: gear selection cable and gear selection cable. Adjust them if necessary.

17. Check for leaks of technical fluids when the engine is running.