Remove/install engine

AR01.10-P-2400CD

Remove/install engine

14.2.12

13.1.06

Bolt, torque converter to drive plate

Transmission 722.6

*BA27.20-P-1002-01C

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

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 areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.

AS83.00-Z-0001-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A



 External torx set

*001589760900

 Torx bit set

*000589011000

 Set of plugs

*129589009100

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground line

AR54.10-P-0003A

2

Pull engine cover upwards off engine

3

Discharge air conditioning system

AR83.30-P-1760GH

4

Remove left and right lamp units

AR82.10-P-4730GH

5

Remove upper radiator crossmember

AR62.30-P-2300GH

6

Remove washer fluid reservoir

7

Remove air filter (18) complete

8

Suction off oil from power steering pump supply reservoir (21)

 Hand pump

*210589007100

9

Remove power steering pump supply reservoir (21) from retaining plate of intake air distribution tube

10

Take off left front wheel



Remove/install wheels, rotate if necessary

AP40.10-P-4050GH

11

Remove left front fender liner

AR88.10-P-1300GH

12

Separate refrigerant line of evaporator/coolant compressor (13) in the left wheel well

 For protection against dirt and moisture, close openings of refrigerant line immediately after separating with suitable plugs.

 Installation: Use new sealing ring. Coat sealing ring and thread with compressor oil before installing.

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

13

Disconnect fuel lines (14) in left wheel well

 Clamp off fuel hoses and seal off lines using suitable plugs. Collect escaping fuel.

 Clamping device

*000589543700

14

Remove bottom section of soundproofing

AR94.30-P-5400GH

Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

15

Drain coolant

 Detach coolant return hose (4) from bottom right of radiator (1).

AR20.00-P-1142HB

16

Disconnect charge air hose of left turbocharger (9), charge air hose on right turbocharger (10) and charge air hose (12) at charge air cooler

17

Unscrew connecting clamps for primary catalytic converters from left and right turbochargers

 At the transmission bell, only unscrew screwed on exhaust bracket after removing the connecting clamps.

 Installation: Bolt on exhaust brackets in front of connecting clamps.



*BA09.40-P-1005-01D

18

Unscrew bolts on transmission bell

 Only slacken both lower bolts at the transmission bell.

 Installation: Screw on bracket for transmission oil filler pipe (27) and exhaust brackets with bolts for transmission bell.



*BA27.40-P-1008-01A

19

Unscrew nuts on left and right engine mounts

20

Unscrew cover of access opening converter (30) at crankcase and unscrew torque converter from driven plate of starter ring gear

 6 bolts. Crank engine by hand as required to gain access to the bolts.



*BA27.20-P-1002-01C

21

Unclip right drain hose (28) and left drain hose (29) at transmission on left and right

 Installation: Guide drain hoses towards rear when introducing the engine.

22

Disconnect coolant vent hose (5) and coolant feed hose (6) at radiator

23

Disconnect oil line of transmission oil cooling (2, 3) at radiator

 Collect escaping oil and seal off connections.

 Installation: Use new sealing rings.



*BA27.55-P-1001-01B



*BA27.55-P-1007-01B

24

Disconnect oil line for steering oil cooling (7, 8) at radiator

 Collect escaping oil and seal off connections.

 Installation: Use new sealing rings.



*BA46.30-P-1012-01A

25

Remove electric fan

AR20.40-P-5000GI

26

Attach guard plate for radiator / condenser to radiator



Guard plate for radiator/condenser

Engine 606 in model 124,

Engine 606.961 in model 140,

Engine 112, 113, 604, 605, 611.960 in model 202,

Engine 602.983, 612.966 in model 461,

Engine 628.962, 612.965, 606.964, 112.945, 113.962 /982 in model 463,

Engine 111, 112, 611.962, 612.962 in model 203,

Engine 112, 113, 611.961, 612.961, 613.961 in model 210,

Engine 112 in model 170,

Engine 112 in model 220,

Engine 113 in model 211, 215, 220,

Engine 112 in model 208,

Engine 112, 113, 612.963, 628.963 in model 163,

Engine 112.923 /943, 113.961 in model 129,

Engine 137, 275 in model 215, 220,

Engine 613.960, 628.960 in MODEL 220,

Engine 113.992 in model 230.474,

Engine 271 in model 209, 203,

Engine 285.950 in model 240.078 /178,

Engine 612.967 in model 209.316,

Engine 648 in model 220

Engine 112.951 in model 639.601/603 /605 /701 /703 /705 /801 /803 /805

Engine 646.983 /984 in model 639.601 / 603 /605 /701 /703 /705 /801 /803 /805

Engine 646.982 in model 639.601 /603 /605 /701 /703 /705

WF58.50-P-0110-01A

27

Disconnect low temperature cooler coolant hose (15, 17) of low temperature cooler at engine

28

Disconnect return coolant hose heater (16) at engine

29

Disconnect connector at left hot film mass air flow sensor (B2/6) and right hot film mass air flow sensor (B2/7)

30

Remove intake air distribution tube (20) with air filter intake hose (24)

 Close charge air intake pipes of turbocharger for protection against foreign objects and dirt with suitable covers, in order to avoid damage to turbochargers.

AR09.10-P-1250CD

31

Remove coolant expansion reservoir (19) from splash wall

32

Detach feed hose for heater heat exchange from left of splash wall

33

Remove hot water circulation pump from battery shield and place to one side with coolant hoses connected

34

Unscrew transmission oil filler pipe (27) from cylinder head cover

35

Remove vacuum line of inlet port shutoff switchover valve (23) and coolant vent hose from housing of fuse and relay module

36

Disconnect vacuum line of inlet port shutoff switchover valve (23) at brake booster

37

Disconnect refrigerant hose of refrigerant compressor/condenser (26) from refrigerant compressor

 Installation: Use new seal. Coat gasket with compressor oil before installing.



*BA83.55-P-1002-01E

38

Disconnect power steering pump pressure line (25) from power steering pump



*BA46.30-P-1003-01A

39

Detach throttle control cable from position sensor (22)

40

Detach position sensor (22) from splash wall

41

Disconnect engine wiring harness

AR01.00-P-2410CD

42

Attach engine hoist with additional cradle to engine

AR01.10-P-2400-03CD

43

Lift engine out of front engine mounts

 Monitor distance between engine and splash wall.

44

Install transmission support

 Pay attention to correct installation of transmission support. The transmission support secures torque converter in its installation position when engine is disconnected.

AR01.10-P-2400-04CD

45

Unscrew lower bolts on transmission bell

46

Guide out engine towards front until it disengages from transmission, and lift out engine

47

Install in the reverse order

48

Pour in coolant

AR20.00-P-1142HB

49

Evacuate air conditioning system, replenish and check for leaks

 Replenish extracted quantity of compressor oil in the refrigerant circuit (fresh oil) when filling the air conditioning system.

 Operating instructions for the individual filling unit must be observed for all operation steps.

AR83.30-P-1760GH

50

Fill power steering pump

AR46.30-P-0010P

Danger!

Risk of accident due to vehicle starting off when engine is running

Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

51

Bleed steering system

 Top up steering gear oil if necessary.

AR46.30-P-0010P

52

Check air conditioning system, oil and coolant connections for leaks with engine running

53

Check oil level in automatic transmission, correct if necessary

 Top up transmission oil if necessary.

AR27.00-P-0100AC

54

Connect STAR DIAGNOSIS and read fault memory

 During repairs, for example, delete the faults stored in the diagnostic trouble code memory by separating the connectors.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
628.962/
963

BA09.40-P-1005-01D

Connection of turbocharger to front catalytic converter

Nm

15

Number

Designation

Trans-mission 722.6
except
722.648

BA27.20-P-1002-01C

Bolt, torque converter to drive plate

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

Number

Designation

Transmission
722.660/661/662/663/666/673/674

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

40

M1090

Nm

40

M12

Nm

-

Number

Designation

Trans-mission 722.6 in model 163

BA27.55-P-1001-01B

Union nut connecting transmission oil line to cooler

Nm

18

BA27.55-P-1007-01B

Banjo bolt, transmission oil line to oil cooler

Nm

30

Number

Designation

Model
163.128/154/157/
172/174/175

BA46.30-P-1003-01A

High-pressure expansion hose to power steering pump

M141.5

Nm

-

M161.5

Nm

45

BA46.30-P-1012-01A

Banjo bolt connecting leak oil line to radiator

Nm

30

Number

Designation

Engine
628.963

BA83.55-P-1002-01E

Bolt, refrigerant line to refrigerant compressor

Nm

20