Remove/install engine with front axle carrier

AR01.10-P-2500MNB

Remove/install engine with front axle carrier

24.03.2020

Engine

178 in model 190

3

Intake air ducts

6

Vent line

7

Separation point

50

Coolant hose

8

Electrical wiring harness

12

Nut

9

Left front partition wall

13

Passage grommet

10

Vacuum line

34

Seal

11

Bolts

4

Coolant hose

19

Vent line

23

Separation point

5

Circulation pump

20

Connection piece

24

Purge lines

16

Fuel supply hose

21

Bleed lines

25

Vacuum hose

17

Cable duct

22

Refrigerant line

26

Vacuum line

18

Cable tie

27

Refrigerant line

28

Separation point

29

Connecting clamp

32

Coolant hose

35

Power steering pump

45

Suction pipe

46

Oil lines

36

Electrical connector

37

Plug connections

38

Ground cable

30

Coolant hose

31

Coolant hose

33

Separation point

40

Bolts

41

Coolant hose

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Topical note

Notes on working in engine compartment

AH60.00-P-0042-01RG

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Notes on repair work on suspension components

AH00.00-P-0100-01A

Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases

AH01.10-P-0001-01A

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 

Remove/install

1

Secure vehicle to prevent it moving away.

2

Move transmission to neutral position and release the parking brake.

3

Move front wheels to straight-ahead position and fix steering wheel in place with holding device.

 Retainer device

*129589012100

4

Secure vehicle on vehicle lift.

AR00.60-P-0100RG

5

Disconnect ground line from battery.

AR54.10-P-0003RG

6

Discharge air conditioning system.

AR83.30-P-1760RQ

7

Remove left and right air filter housing.

AR09.10-P-1150MNB

8

Remove seal (34).

9

Unclip electrical wiring harness (8) at front left partition (9).

10

Remove vacuum line (10) at brake booster and remove upwards.

11

Remove screws (11).

 Bolt, partition wall to body

*BA68.74-P-1001-01D

12

Unscrew nut (12).

 Nut, partition wall to body

*BA68.74-P-1002-01D

13

Lift front left partition (9) and remove feed-through grommet (13).

14

Remove front left partition (9) upwards.

15

Remove engine wiring harness to remove engine.

AR01.00-P-2410-03MNB

 Nut, positive line to alternator

*BA15.40-P-1003-01T

 Nut, connection for terminal designation 30

*BA15.30-P-1004-01T

 Nut, connection for terminal designation 50

*BA15.30-P-1003-01T

 Bolt, ground line to front axle carrier

*BA15.10-P-1002-05F

16

Remove ME-SFI [ME] control unit (N3/10).

AR07.08-P-1000MNB

17

Remove left charge air cooler from pilot bushings.

AR09.41-P-6827MNB

18

Remove right charge air cooler from pilot bushings.

AR09.41-P-6828MNB

19

Remove intake air ducts (3).

 Clamp, boot to exhaust gas turbocharger/air filter

*BA01.20-P-1003-01J

20

Remove center and front section of lower engine compartment lining.

AR61.20-P-1105RG

 Installation: Only install center and front section of lower engine compartment lining after the leak test.

21

Drain coolant at radiator.

AR20.00-P-1142MNB

22

Remove coolant hose (4) at circulation pump (5).

 Hose clamp pliers

*003589033700

23

Unclip coolant hose (4) at bracket of ME-SFI [ME] control unit (N3/10).

24

Unclip bleed line (6) at coolant expansion reservoir and at bracket of coolant expansion reservoir.

25

Release and disconnect bleed line (6) at separating point (7).

AR20.20-P-7441-01RQ

26

Remove coolant hose (50) at coolant line.

 Hose clamp pliers

*003589033700

27

Release fuel pressure via service connection.

AR07.03-P-1460-01MNA

 Dust protection cap to service connection

*BA07.03-P-1005-01H

 Pressure hose

*119589046300

28

Remove fuel supply hose (16) at service connection of low-pressure line and seal openings with suitable stop plugs.

 Union nut, fuel hose to diagnostic socket/fuel line

*BA07.03-P-1006-01H

 Record plug

*129589009100

29

Remove left cable duct (17).

30

Cut cable tie (18).

 Installation: Replace cable tie (18).

31

Remove bleed line (19) at connection piece (20).

 Hose clamp pliers

*003589033700

32

Unclip bleed lines (21) at bracket of purge valves and place to one side.

33

Remove refrigerant line (22) at separating point (23), place refrigerant line (22) to one side and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring of refrigerant line (22) and wet with compressor oil.

 Nut/bolt, refrigerant line to condenser/separating point

*BA83.30-P-1006-01M

 Record plug

*129589009100

34

Remove purge lines (24) at purge valve and seal openings with suitable stop plugs.

 Installation: Replace snap clamps.

 Record plug

*129589009100

 Pliers for click clamps

*171589003700

35

Remove steering coupling from steering shaft.

AR46.10-P-8000RG


Do not turn steering wheel with steering coupling removed.
Otherwise, the clock spring contact is damaged.

36

Remove vacuum hose (25) at vacuum line (26).

 Installation: Replace click clip at vacuum hose (25).

 Pliers for click clamps

*171589003700

37

Remove left and right circulation pump for low-temperature water circuit.

AR09.41-P-6925MNB

38

Remove left and right lower charge air hose.

AR09.41-P-1311-01AL

39

Remove refrigerant line (27) at separating point (28) and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring of refrigerant line (27) and wet with compressor oil.

 Nut/bolt, refrigerant line to condenser/separating point

*BA83.30-P-1006-01M

 Record plug

*129589009100

40

Remove bracket of refrigerant line (27) at front axle carrier.

 Bolt, refrigerant line to integral carrier

*BA83.30-P-1007-01M

41

Remove oil lines (46) at crankcase.

 Collect engine oil which flows out in a suitable vessel.

 Installation: Replace sealing rings of oil lines (46).

 Engine 178.9 in model 190Bolt, oil line to crankcase/engine support/oil pan (oil filter housing)

*BA18.30-P-1010-01N

42

Remove bracket of oil lines (46) at front axle carrier.

 Engine 178.9 in model 190Bolt, oil line to front axle carrier

*BA18.30-P-1008-01N

43

Remove connecting clamp (29) and place oil lines (46) to one side.

44

Remove left front fender liner.

AR88.10-P-1300RG

45

Remove both oil lines at oil reservoir.

AR18.00-P-1000MNB

46

Remove coolant hoses (30, 31).

AR20.20-P-7441-01RQ

47

Remove bracket of coolant hose (32) at front axle carrier.

48

Remove coolant hose (41) at separating point (33) and place to one side.

 Hose clamp pliers

*003589033700

49

Remove suction line (45) at power-steering pump (35) and seal openings with suitable stop plugs and/or protective covers.

AR46.30-P-0500RG

 Set of protective caps

*001589009100

 Record plug

*129589009100

50

Remove mounting clamp of oil line of steering at rack-and-pinion steering.

51

Remove oil lines at rack-and-pinion steering and seal openings with suitable stop plugs.

 Collect escaping steering gear oil with suitable container.

 Bolt, high pressure line to steering gear

*BA46.30-P-1004-01E

 Record plug

*129589009100

52

Remove front right wheel and tire assembly.

AR40.10-P-1100RQ

53

Remove left and right lower transverse control arm at front axle carrier.

AR33.20-P-0510RG

54.1

Remove left and right tie rod at steering knuckles.

Model 190 with engine 178
except code 201 (Rear axle steering)

AR35.20-P-0109RQ

54.2

Remove left actuator and right actuator of rear axle steering.

Model 190 with engine 178
with code 201 (Rear axle steering)

AR46.80-P-0012RG

55

Remove exhaust system.

Engine 178 in model 190.379/380/477/478/479/480

AR49.10-P-7142MNC

Engine 178 in model 190.377/378

AR49.10-P-7142MNB

56

Remove bracket of left oil lines at transmission.

AR27.55-P-0612MNB

57

Remove left oil lines at transmission.

AR27.55-P-0612MNB

58

Remove right oil lines at separating point.

AR27.55-P-0613MNB

59

Remove left and right rear axle shaft at transmission.

AR35.30-P-0620RQ

60

Support front axle carrier with lifting platform.

AR33.10-P-0050-01RQ



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

61

Support transmission using major assembly mount and support plate.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

62

Remove transmission mount with transmission mount mounting console.

AR27.10-P-1000MNB

63

Slightly lower transmission with major assembly mount and mounting plate.



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B


Only lower the transmission until no assembly parts impact or the wiring harnesses are not under tension.
Otherwise damage can occur to the assembly parts, wiring harnesses and the body.

64

Release and disconnect electrical connector (36).

65

Release and disconnect electrical connectors of plug connections (37) at transmission.

66

Remove ground line (38) from transmission.

 Engine 178 in model 190Transmission ground point

*BA00.19-P-1030-01K

67

Disconnect cable tie of transmission wiring harness at left transmission carrier.

 Installation: Replace cable tie of transmission wiring harness.

68

Remove screws (40) at front axle carrier.

 Installation: First screw centering pins into left and right longitudinal members and slide front axle carrier with centering onto centering pins.

 Installation: Replace screws (40).

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01N

 Centering pin

*197589006100

69

Uniformly lower engine-transmission unit with front axle carrier.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Engine-transmission unit may not bump into body panels or major assemblies. Do not crush or subject lines and hoses to tension.
Otherwise damage will occur.

 Installation: Two helpers required.

70

Install in the reverse order.

Concluding tasks

71

Check engine oil level and correct if necessary.



AP18.00-P-1811MP

72

Check and correct transmission oil level.



AP27.00-P-2701RQ

73

Check engine cooling system for leak tightness.

AR20.00-P-1010MNB

74

Perform chassis alignment.

AR40.20-P-0200RQ

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

75

Perform engine test run and check engine and transmission for proper operation and leak tightness while doing so.

 Ground points

Number

Designation

Model 190

BA00.19-P-1030-01K

Transmission ground point

W49

Nm

8

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 178

BA01.20-P-1003-01J

Clamp, boot to exhaust gas turbocharger/air filter

Nm

1,5

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1005-01H

Dust protection cap to service connection

Nm

1

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1006-01H

Union nut, fuel hose to diagnostic socket/fuel line

Nm

24

 Ground strap

Number

Designation

Engine 178

BA15.10-P-1002-05F

Bolt, ground line to front axle carrier

Nm

20

 Starter

Number

Designation

Engine 178

BA15.30-P-1003-01T

Nut, connection for terminal designation 50

Nm

9

 Starter

Number

Designation

Engine 178

BA15.30-P-1004-01T

Nut, connection for terminal designation 30

Nm

16

 Alternator

Number

Designation

Engine 178

BA15.40-P-1003-01T

Nut, positive line to alternator

Nm

16

 Oil cooling

Number

Designation

Engine 178

BA18.30-P-1008-01N

Bolt, oil line to front axle carrier

Nm

9

 Oil cooling

Number

Designation

Engine 178

BA18.30-P-1010-01N

Bolt, oil line to crankcase/engine support/oil pan (oil filter housing)

Nm

9

 Front axle carrier

Number

Designation

Model 190

BA33.10-P-1001-01N

Bolt, front axle carrier to longitudinal member

Nm

160

 Power steering pump

Number

Designation

Model 190

BA46.30-P-1004-01E

Bolt, high pressure line to steering gear

Nm

21

 Partition wall

Number

Designation

Model 190

BA68.74-P-1001-01D

Bolt, partition wall to body

Nm

7

 Partition wall

Number

Designation

Model 190

BA68.74-P-1002-01D

Nut, partition wall to body

Nm

8

 Air conditioning

Number

Designation

Model 190

BA83.30-P-1006-01M

Nut/bolt, refrigerant line to condenser/separating point

Nm

12

 Air conditioning

Number

Designation

Model 190

BA83.30-P-1007-01M

Bolt, refrigerant line to integral carrier

Nm

8