Remove/install engine with front axle carrier

AR01.10-P-2500GF

Remove/install engine with front axle carrier

10.11.11

 

Remove/install

 Danger!

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

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

AS00.00-Z-0010-01A

1.1

Unscrew oil drain screw from oil pan at automatic transmission and drain ATF

Only on vehicles fitted with transmission 722.7.

 Installation: Replace sealing ring.



*BA27.10-P-1001-03A

2

Drain coolant at radiator and crankcase

AR20.00-P-1142GF

3

Disconnect battery ground line

AR54.10-P-0003A

4.1

Remove washer fluid reservoir

Only for vehicles with code (875) Heated windshield washer system.

5

Detach ground cable at right front engine support

6

Remove air intake scoop (1), air intake hose (2) and resonator (3)

 A resonator (3) is only installed for engine 166.960/990

7

Detach vacuum line (5) at intake manifold

8

Release and unplug vehicle wiring harness connector (12) on ECM [MSM] control unit (N3/5). Separate cable tie

Shown on vehicle up to 28.2.01

 Release and disconnect connector (white arrow).
 Installation: Insert plug into guide, establish connections and lock (black arrow).

 Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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

9

Disconnect fuel line (15) at fuel distributor

 Seal fuel line (15) with a suitable plug.

10

Detach vacuum line (16) of purge valve

11

Detach vacuum lines (17) at intake manifold, detach along fuel rail and place to the side

12.1

Remove coolant hoses (13, 14)

Vehicles without a separate coolant expansion reservoir.

 Installation: Replace hose clamps.

12.2

Remove coolant hoses (50, 52, 62) on coolant expansion reservoir (49), unlock striker on coolant expansion reservoir (49) (arrow) and remove coolant expansion reservoir (49).

On vehicles with a separate coolant expansion reservoir

 Installation: Replace hose clamps.



Radiator with separate coolant expansion reservoir

Engine 166 in model 168 as of 1.6.99

BT20.30-P-0001-01GF

13

Remove coolant hose (51) below on radiator and coolant hose (53) on the side on longitudinal member (arrow)

 Installation: Replace hose clamps.

14

Detach coolant hose (6) at coolant thermostat

 Installation: Replace hose clamps.

15.1

Detach oil lines (54) at oil cooler and seal with a suitable plug

Only models fitted with transmission 722.7.

 The oil cooler is integrated within the radiator.



*BA20.20-P-1002-01C

16

Remove heating feed and heating return flow coolant hoses (23, 24)

 Installation: Replace hose clamps.

17

Detach steering coupling (27) at steering shaft (28), take off thrust piece (29)

 Installation: Replace self-locking collar nut (31) or nut bracket (59).



*BA46.10-P-1002-01C

18

Disconnect positive line (25) and control line (26) for power steering pump at left frame longitudinal member

19

Detach shift cables (21, 22) by turning locknuts counterclockwise, releasing them from the bracket and then unsnapping the shift cables from the ball joints

 Installation: Ensure that shift cables (21, 22) are securely attached to the ball heads.

20.1

Disconnect electrical connectors to turning angle sensors, expose electrical line and place to one side

Only on models fitted with automatic clutch system (code 421)

21.1

Detach hose (61) at the air pump (60)

Only for vehicles from 1.3.01

22

Detach suspension strut (37) at suspension strut dome

 Installation: Lead guide pin on suspension strut (37) into guides (arrow) on the suspension strut tower.



*BA32.25-P-1002-04A

23

Detach floating caliper (40) at steering knuckle, tie up in wheelhousing together with brake pads and connected brake hose

 Installation: Replace self-locking bolts (41).



*BA42.10-P-1001-10O

24

Disconnect plug connection for brake pad contact sensor (39) and plug connection for front axle speed sensor (38) in top of wheelhousing; expose cable

 The plug connection for brake bad contact sensor (39) is only installed at the front right.

25.1

Remove collar clamp (11) and separate flange connection between catalytic converter (7) and exhaust system

In vehicles as of 1.3.01

25.2

Remove screw/bolt (10) and disconnect exhaust system flange connection (7) at catalytic converter

In vehicles up to 28.2.01



 Installation: Replace seal (8), check condition of flange connection rivet nut,  if necessary

*BA49.10-P-1001-01D

Replace rivet nut of flange connection

AR14.10-P-4095-01GF

26.1

Take cable of O2 sensor downstream of catalytic converter (G3/1) out of retaining clip (arrow) at underfloor and separate plug connection

Only for vehicles from 1.3.01

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

27

Remove locking element (20) and pull clutch hose (18) out of the transmission from below

 Seal clutch hose (18) with a suitable plug.

 Installation: Replace sealing ring (19) and securing device (20).



Brake fluid notes

All models

AH42.50-P-0001-01A

28.1

Release the poly-V belt (47) and remove it from refrigerant compressor (A9)

Only on vehicles with code (580) Air conditioning or for USA Tempmatic

AR13.22-P-1202GF

29.1

Detach refrigerant compressor (A9) and attach it to the underbody with the connected refrigerant lines and electrical lines

Only on vehicles with code (580) Air conditioning or for USA Tempmatic

30

Prepare front axle carrier removal fixture (48)

 Risk of tipping during later lowering - note location of the adapter. Adapter modification required from model refinement package 03/2001 or VIN "WDB1680311J568590" .

Also from VIN "WDB1680311J568590"

Jack assembly adapter gotis://A_25/35/49_03.0

31

Align front axle carrier removal fixture (48) at front axle carrier (32) and fit evenly

 Risk of tipping during later lowering.

Also from VIN "WDB1680311J568590"

32

Take off struts (34) at front axle carrier (32) and at underfloor



*BA33.10-P-1003-01B

33

Take off wheelhousing liners on left and right at underfloor and fold down

 To gain access to the rear screw/bolts (33).

34

Unscrew screw/bolts (33) (8 pcs.)


 Installation: First fit all the Screw/bolts (33), then tighten.

*BA33.10-P-1001-01B

35

Carefully lower engine together with front axle carrier (32) far enough to gain access to starter (M1) and alternator (G2)

 Proceed with caution to avoid damaging coolant hoses, AC hoses and electrical wiring.

 Installation: Guide (arrow) on the front axle carrier (32) must be inserted in the bore in the longitudinal member.

36.1

Unhook shift cable (57) from shift linkage, remove bracket (56) from transmission and take out of support (arrow). Unlock plug (58) on transmission (arrow) and detach

Only models fitted with transmission 722.7.

37

Disconnect ground cable (44) together with fixture at oil pan

38

Remove starter wiring harness (43) on starter (M1)

 Terminal 50

*BA15.30-P-1002-01B

 Terminal 30

*BA15.30-P-1003-01B

39

Remove alternator wiring harness (42) on alternator (G2)

 Circuit D+

*BA15.40-P-1001-01B

 Circuit B+

*BA15.40-P-1002-01B

40

Carefully lower engine with front axle carrier (32) fully

 Proceed with caution to avoid damaging coolant hoses, a/c hoses and electrical wiring.

41

Install in the reverse order

 Danger!

Risk of accident caused by vehicle starting off by itself 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 appropriate work clothes when carrying out work on the vehicle.

AS00.00-Z-0005-01A

42.1

Check oil level in automatic transmission; fill with oil if necessary

Only on vehicles fitted with transmission 722.7.

AR27.00-P-0101GC

43

Bleed clutch operating system

AR25.20-P-0070GC

44

Inspect cooling system for leaks

AR20.00-P-1010GF

Number

Designation

Engine
166.940/
960/ 990/
995

BA15.30-P-1002-01B

Cable to starter circuit 50

Nm

6

BA15.30-P-1003-01B

Cable to starter circuit 30

Nm

9

Number

Designation

Engine 166.940/
960/ 990/
995

BA15.40-P-1001-01B

Cable to alternator terminal D+

Nm

6

BA15.40-P-1002-01B

Cable to alternator terminal B+

Nm

18

Number

Designation

Engine 166.940/
960/990/
995

BA20.20-P-1002-01C

Union nut, automatic transmission oil line to radiator

Nm

25

Number

Designation

Trans-mission 722.3

Trans-mission 722.4/5/7

BA27.10-P-1001-03A

Drain plug on transmission oil pan

Nm

14

22

Number

Designation

Model 168.006/
007/008/
009/031/
033/032/
035/109/
131/132/
133/135

BA32.25-P-1002-04A

Screw/bolt, suspension strut to suspension strut dome

Nm

40

Number

Designation

Model 168

BA33.10-P-1001-01B

Screw/bolt, front-axle carrier to body

M 12

Nm

120

BA33.10-P-1003-01B

Strut bolt on front-axle carrier
and body

M 10

Nm

60

Number

Designation

Model
168

BA42.10-P-1001-10O

Self-locking bolt, brake caliper to steering knuckle

Nm

115

Number

Designation

Model 168

BA46.10-P-1002-01C

Screw/bolt, steering coupling to steering shaft

Nm

20

Number

Designation

Engine 166.940/
960/990/
995

BA49.10-P-1001-01D

Screw/bolt of exhaust system to catalytic converter

Nm

25