Remove/install engine

AR01.10-P-2400MB

Remove/install engine

14.2.12

26.5.03

Safety information on battery, incorporated for the first time

Operation step 2

26.5.03

Safety note for hydraulic fluid, added

 

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 injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

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.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

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

1

Move selector lever to position "D"

 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

2

Disconnect battery ground line

 Do not connect quiescent current retention unit.

AR54.10-P-0003I

3

Open engine hood and raise to vertical position

AR88.40-P-1000M

4

Remove air filter housing (1).

AR09.10-P-1050M

5

Remove front engine cover (2)

AR01.10-P-2405M

6

Remove left and right hot film MAF sensor with air intake pipe

AR07.07-P-1454M

7

Remove bottom sections of soundproofing

 Installation: Only install soundproofing bottom section after the engine test run.

AR94.30-P-5300M

 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

8

Drain coolant at radiator

AR20.00-P-1142HB



*BF20.00-P-1001-02E

9

Remove fan shroud (3)

AR20.40-P-6800MB

10

Attach protective plate (010) for radiator



Guard plate for radiator/condenser

WF58.50-P-0110-01A

11

Attach engine hoist

AR33.10-P-0105M



*BA22.10-P-1001-01D

12

Remove charge air cooler (25)

AR09.41-P-6817MA

13

Remove poly-V belt

AR13.22-P-1202M

14

Remove complete exhaust system

AR49.10-P-7000MB

15

Remove upper left charge air intake pipe (4)

AR09.41-P-1319M

16

Remove lower left charge air pipe (5)

 Do not lower front axle; lift engine using the engine lifting device.

AR09.41-P-1316M

17

Detach refrigerant compressor (A9) from crankcase

 Do not remove refrigerant lines.



*BA83.55-P-1001-01E

18

Detach pneumatic line (81) from inlet port shutoff switchover valve (Y83)

19.1

Remove expansion reservoir for power steering and Active Body Control (ABC)

For Active Body Control (ABC), code 487a

AR46.25-P-1000M

 Hand pump

*210589007100

19.2

Remove power steering expansion reservoir

Except Active Body Control (ABC),
code 487a

AR46.25-P-1000MA

20.1

Disconnect high pressure line (29) for power steering pump on clutch (arrow)

Except Active Body Control (ABC),
code 487a



*BA46.30-P-1017-01C

21.1

Remove line (6) from pressure supply valve unit (52)

For Active Body Control (ABC), code 487a

 Seal connections immediately.

Attach pressure supply valve unit (52) in place using a cable tie on the front axle carrier.

 Installation: Replace O-rings.



*BA32.50-P-1017-01A

 Set of plugs

*129589009100

22.1

Remove pressure hose (7a) from pressure line (7b)

 Seal connections immediately.

 Installation: Install new O-ring.



*BA46.30-P-1017-01C

23

Drain engine oil



Engine oil and filter change

AP18.00-P-0101AT

24

Disconnect engine wiring harness

 Disconnect all connectors which are accessible when the vehicle is raised.

AR01.00-P-2410MB

25

Remove shift rod

AR27.60-P-0990I

26

Remove propeller shaft from drive flange of transmission

AR41.10-P-0050I



*BA41.10-P-1001-01A

27

Remove rear engine mount from rear engine crossmember

AR22.10-P-1160AB



*BA22.10-P-1002-01D

28

Remove engine lifting device

 Removal: Do not mount engine mount on front axle carrier.

AR33.10-P-0105M

29

Disconnect engine wiring harness

 Disconnect all connectors which are accessible when the vehicle is lowered.

AR01.00-P-2410MB

30

Remove coolant hoses (8a, 8b)

Hose clamp pliers

31

Remove coolant hoses (9a, 9b) on coolant pump

7 mm wrench socket on flexible shaft

Socket sets

gotis://G_58.3__06.0

32

Remove coolant line (10)

33

Remove coolant hose (11) from vent line (12)

34

Remove coolant hose (13) from connection fitting (14) to heating system heat exchanger

Hose clamp pliers with Bowden cable

35

Remove automatic oil line (15a)



*BA27.55-P-1001-01B

36

Remove automatic oil line (15b) from radiator



*BA27.55-P-1001-01B

36

Remove vacuum line to brake booster

 The vacuum line is constructed in two pieces. Only remove section on the brake booster.

AR43.10-P-0355M

37

Detach fuel hoses (16a, 16b) from the fuel lines (17a, 17b)

 Installation: Replace hose clamps.

 Clamping device

*000589403700

38

Remove firewall (18)

39

Lift engine and lift out of engine compartment

AR01.10-P-7500-03M

Load regulator
gotis://H_00.12_04.0

40

Install in the reverse order

41.1

Fill and bleed power steering pump and Active Body Control (ABC)

For Active Body Control (ABC), code 487a

 Fill and bleed both systems simultaneously, otherwise the power steering pump will be damaged.

Fill power steering pump and bleed

AR46.30-P-0010N

 Power steering

*BF46.20-P-1001-01A

Fill and bleed active body control (ABC)

AR32.50-P-0021N

 Active Body Control (ABC)

*BF32.50-P-1001-01A

41.2

Fill power steering pump and bleed

Except Active Body Control (ABC),
code 487a

AR46.30-P-0010I

 Power steering

*BF46.20-P-1001-01A

42

Inspect cooling system for leaks

AR20.00-P-1010HA

43

Check oil level in automatic transmission, correct if necessary

AR27.00-P-0100AC

44

Check leaktightness of all systems on a running engine

45

Read out fault memory

STAR DIAGNOSIS diagnosis system



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine 628.960
in model 220

BA22.10-P-1001-01D

Screw/bolt, front engine mount to front axle carrier

Nm

35

BA22.10-P-1002-01D

Screw/bolt, rear engine mount to rear engine crossmember

Nm

30

Number

Designation

Trans-mission 722.6 in model 170, 171, 203, 209, 210, 215, 219, 220, 230, 240

BA27.55-P-1001-01B

Union nut connecting transmission oil line to cooler

Nm

25

Number

Designation

Model
220

BA32.50-P-1017-01A

Banjo bolt on pressure supply valve unit

Nm

40

Number

Designation

Model
220

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

-

M12

Nm

60

Number

Designation

Model
220.028/128 without code 487a

Model
220.028/128
with code 487a

BA46.30-P-1017-01C

Union nut, high pressure hose to power steering pump high-pressure line

Nm

40

40

Number

Designation

Engine
628.960/
961

BA83.55-P-1001-01E

Screw/bolt, refrigerant compressor to cylinder crankcase

Nm

20

Number

Designation

Engine
628.960

BF20.00-P-1001-02E

Cooling system

Total filling capacity

Liters

16.5

Filling capacity of anticorrosion/
antifreeze down to -37°C

Liters

8.25

Filling capacity of anticorrosion/
antifreeze down to -45°C

Liters

9.1

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Number

Designation

Model
220
without code 487

Model
220
with code 487

BF46.20-P-1001-01A

Power steering

Filling capacity

Liters

1.0

1.25

MB steering gear oil

Sheet

BB00.40-P-0345-00A

BB00.40-P-0345-00A

Number

Designation

Model 220

BF32.50-P-1001-01A

Filling capacity

Initial charge

Liters

4

Specifications for Operating Fluids

Sheet

BB00.40-P-0345-00A