Remove/install engine with transmission

AR01.10-P-2401MRF

Remove/install engine with transmission

26.06.2019

Engine

274.9 in model 238

except code M005 (4MATIC)

1

Vacuum line

7

Coolant hose

2

Coolant hose

8

Coolant vent lines

3

Purge line

9

Coolant hose

4

Coolant line

10

Diagnostic socket

5

Coolant hose

11

Fuel hose

6

Coolant hose

 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

 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 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

 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 bolted connections with self tapping screws

AH00.00-P-0007-01SF

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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Notes on AIR BODY CONTROL

Engine 274.9 in model 238
with code 489 (AIR BODY CONTROL)
except code M005 (4MATIC)

AH32.22-P-1000-03LWO

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

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

AH01.10-P-0001-01A

 

Remove/install

1

Secure vehicle against rolling

2

Shift transmission to neutral and release parking brake

3

Secure vehicle on vehicle lift

AR00.60-P-0100CW

4

Reduce pressure in air suspension with vehicle diagnosis system

Engine 274.9 in model 238
with code 489 (AIR BODY CONTROL)
except code M005 (4MATIC)



AD00.00-P-2000-06LWO

5

Disconnect ground line from battery

AR54.10-P-0003LWO

6

Remove upper engine cover

 Installation: Only install upper engine cover after the leak test.

7

Remove bottom engine compartment paneling

AR61.20-P-1105LWE

 Installation: Only install lower engine compartment paneling after leak test.

8

Relieve fuel pressure at diagnostic socket (10)

AR07.03-P-1460-01MR

 Dust cap at service connection

*BA07.03-P-1003-01F

 Pressure hose

*119589046300

9

Drain off coolant

AR20.00-P-1142OLC

10

Remove drain screw from oil pan and collect engine oil in suitable container

Notes on engine oil and filter changes

AH18.00-P-0104-01A

 Installation:
Use only approved engine oils.
Engine damage will occur otherwise.

 Installation: Replace sealing ring.

 Drain screw to oil pan

*BA01.45-P-1002-01T

 Engine 274.9 in model 238 (except 238.343/443)
except code M005 (4MATIC)Engine oil

*BF18.00-P-1001-01ZA

11

Remove propeller shaft from transmission output flange and secure against falling down

AR41.10-P-0050LW

12

Remove center shifter console and shift rod on transmission

Engine 274.9 in model 238 with transmission 716.7
except code M005 (4MATIC)

AR26.60-P-0600LW

13

Remove hydraulic line from clutch slave cylinder and seal openings with suitable stop plugs

Engine 274.9 in model 238 with transmission 716.7
except code M005 (4MATIC)

AR25.20-P-0150LW

 Record plug

*129589009100

14

Remove rear engine mounts

AR22.10-P-1160MRD

 The rear engine support remains on the vehicle.

15

Remove fuel hose (11) from engine, collect escaping fuel in suitable container and seal openings with suitable stop plugs

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

16

Remove coolant line to low-temperature water circuit radiator on oil cooler for the A/T

Engine 274.9 in model 238 with transmission 725.0
except code M005 (4MATIC)

AR20.20-P-7441-01RQ

17

Remove automatic transmission oil cooler from fan unit and secure with connected lines to engine against falling down

Engine 274.9 in model 238 with transmission 725.0
except code M005 (4MATIC)

AR27.55-P-1000OLD

18

Remove catalytic converter

AR49.10-P-5500MRD

19

Remove fan unit

AR20.40-P-5050OLA

20

Mount protective plate on radiator



WF58.50-P-0110-01A

21

Detach engine wiring harness to remove engine

AR15.18-P-1000-05MRD

 M61

*BA00.10-P-1002-04A

 Nut, positive line to busbar on firewall

*BA54.18-P-1001-02C

 Bolt/nut, ground line to transmission/underfloor

*BA00.19-P-1039-02B

22

Unclip ME-SFI [ME] control unit (N3/10) and secure with connected line to engine against falling down

AR07.08-P-7013MRD

23

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

24

Remove vacuum line (1) from vacuum pump

25

Remove coolant bleed lines (8) from cylinder head cover and charge air cooler

 Hose clamp pliers

*003589033700

26

Remove coolant hose (9) from engine

 Hose clamp pliers

*003589033700

27

Remove coolant hose (2) from bulkhead

AR20.20-P-7441-01RQ

28

Remove coolant hoses (6, 7)

AR20.20-P-7441-01RQ

29

Remove bracket for coolant line (4) from timing case cover

 M61

*BA00.10-P-1002-04A

30

Remove coolant line (4) from charge air cooler

AR20.20-P-7441-01RQ

31

Remove coolant hose (5) from charge air cooler

AR20.20-P-7441-01RQ

32

Release and disconnect purge line (3) at charge air cooler and seal openings with suitable stop plugs

 Record plug

*129589009100

33

Release and disconnect inerting system line at firewall and seal openings with suitable stop plugs

Engine 274.9 in model 238
with code 2U8 (Alternative refrigerant)
except code M005 (4MATIC)

AR86.10-P-0419LWE

 Record plug

*129589009100

34

Remove poly-V belt

AR13.22-P-1202MRD

35

Release and disconnect electrical connector of refrigerant compressor (A9)

36

Remove refrigerant compressor (A9) from crankcase, place with connected refrigerant lines to one side and secure against falling down

 Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

*BA83.55-P-1001-01M

37

Attach load tilter to all available engine lifting lugs as well as to boom crane and slightly lift engine



000 588 00 62 00 Load tilter

WS01.00-P-0102B


When lifting engine, do not subject engine mounts to tension.
Otherwise, engine mounts are damaged.

 Commercially available devices/tools
Boom crane

38

Remove front engine mounts from engine supports

AR22.10-P-4330MRD

39

Lift out the engine together with the transmission



000 588 00 62 00 Load tilter

WS01.00-P-0102B


When lifting out/in engine with transmission, do not damage any lines or hoses.
Otherwise leaks and engine damage can occur.

 Commercially available devices/tools
Boom crane

 Two helpers required.

40

Install in the reverse order



Check

41

Check engine oil level; correct if necessary



AP18.00-P-1811MP

42

Check installation position and unobstructed movement of all components of the exhaust system

 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

43

Perform engine test run and check engine and transmission for proper operation and leak tightness

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Ground points

Number

Designation

Model 238

BA00.19-P-1039-02B

Bolt/nut, ground line to transmission/underfloor

M8

Nm

20

 Oil pan

Number

Designation

Engine 274

BA01.45-P-1002-01T

Drain screw to oil pan

Nm

40

 Injection nozzles, injection valves, lines

Number

Designation

Engine 274

BA07.03-P-1003-01F

Dust cap at service connection

Plastic

Nm

2

Metal

Nm

15

 Wiring harness

Number

Designation

Model 238

BA54.18-P-1001-02C

Nut, positive line to busbar on firewall

M6

Nm

8

M8

Nm

16

 Refrigerant compressor

Number

Designation

Engine 274

BA83.55-P-1001-01M

Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

Nm

20

 Engine lubrication

Number

Designation

Engine 274.91 in model 205, 213
Engine 274.92 in model 205, 213, 238, 253
except code M005 (4MATIC)

BF18.00-P-1001-01ZA

Engine oil

Oil filling capacity with oil filter

l

7

Sheet

BB00.40-P-0223-02A