Remove/install engine with transmission · ar0110p2401mt · Mercedes-Benz WIS

AR01.10-P-2401MT

Remove/install engine with transmission

24.03.2020

Engine

270 in model 117, 156, 176, 242, 246.2

P01.10-3476-08

Shown on model 246.242 with transmission 724.0

1	Radiator	8	Vent line	14	Fan unit
2	Coolant hose	9	Coolant hose	15	Air cleaner housing
3	Coolant hose	10	Refrigerant line	16	Battery box
4	Coolant hose	11	Refrigerant line	23	Refrigerant line
5	Charge air hose	12	Condenser	29	Radiator support
6	Coolant hose	13	Charge air cooler

Shown on model 246.242

2	Coolant hose
6	Coolant hose
8	Vent line
9	Coolant hose
15	Air cleaner housing
16	Battery box
17	Purge line
18	Coolant hose
19	Coolant hose
20	Vacuum line
22	Electrical line
23	Refrigerant line
27	Fuel line
M13/5	Coolant circulation pump
Y77/1	Boost pressure control pressure transducer

P01.10-3098-06

Shown on model 246.242

23	Refrigerant line
24	Engine support frame
25	Motor
26	Tensioning strap
M13/7	Transmission oil cooling coolant circulation pump

P01.10-3099-11

 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
 Danger	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
 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
 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
 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
Topical note	Notes on avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
Topical note	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
Topical note	Notes on threaded connections fastened using a tightening angle-based tightening process		AH00.00-P-0020-01A
Topical note	Notes on working on natural gas powered vehicles	Model 242 with engine 270 with code 924 (Bivalent natural gas drive)	AH00.10-P-1000-06A
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
	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
	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	Unclip cover on the gearshift lever and pull over the gearshift lever.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 711.6
			AR68.20-P-2350NKB
3	Move shift module to 2nd gear and lock using a suitable drift.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 711.6
			AR26.60-P-0635-02NKB
4	Release parking brake.
5	Secure vehicle on vehicle lift.		AR00.60-P-0100CW
6	Remove front wheel and tire assemblies.
			AP40.10-P-4050AK
7	Remove rear section of the bottom engine compartment lining.		AR61.20-P-1105NKB
		 Installation: Only install the rear section of the lower engine compartment paneling after the leak test.
		 The front section of the lower engine compartment lining remains on bumper.
8	Remove left and right front fender liner.		AR88.10-P-1300NKB
9	Remove washer fluid reservoir of the windshield washer system.		AR82.35-P-6000NKB
10	Remove front bumper from the front fenders.	Engine 270 in model 156	AR88.20-P-2000NKX
		Engine 270 in model 117, 176, 242, 246.2	AR88.20-P-2000NKB
		 The front bumper remains on the front module.
11	Remove engine air intake duct upstream of air filter.
12	Remove battery .		AR54.10-P-0005NKB
13	Remove top radiator holders.		AR20.20-P-3865NKB
14	Remove cover from hood lock.
15	Release and disconnect electrical connector from hood catch.
16	Unhook cable for releasing the hood and lay down outside of the working area.
17	Release and disconnect electrical connectors from the front left lamp unit and from the front right lamp unit.	Engine 270 in model 156	AR82.10-P-4730NKX
		Engine 270 in model 117, 176, 242, 246.2	AR82.10-P-4730NKB
18	Remove front end module completely.		AR62.30-P-1570NKB
19	Remove center muffler from catalytic converter.	Engine 270 in model 117, 156, 246 except code 598 (Gasoline particulate filter (OPF) with sensor system) Engine 270 in model 176, 242	AR49.10-P-4816MT
		Engine 270 in model 117, 156, 246 with code 598 (Gasoline particulate filter (OPF) with sensor system)	AR49.10-P-4816MTA
20	Drain coolant at radiator (1).		AR20.00-P-1142NKB
21	Remove front axle shafts.		AR33.30-P-0620NKB
22	Hook supporting joint of the transverse control arms into the steering knuckles.		AR33.20-P-0510NKB
23	Remove propeller shaft from power take-off and secure against falling down.	Engine 270 in model 117, 156, 176, 246.2 with code M005 (Vehicles with 4MATIC/all-wheel drive)
			AR41.10-P-0050-18MTA
			WF58.50-P-4110-01A
		Thread locking adhesive, Loctite 241	*BR00.45-Z-1001-02A
		 Bolt, drive shaft to transmission	*BA41.10-P-1001-01K
		 Counterholder	*176589004000
 Danger	Risk of explosion due to escaping combustible gas or overheating of gas cylinders.Risk of injury caused by burns to skin and eyes. Risk of frostbite to body parts caused by escaping gas and by touching components near the valves when emptying gas cylinders. Risk of poisoning or suffocation caused by inhaling gas.	Remove any sources of ignition. Protective clothing, safety gloves and safety glasses must always be worn. Ensure that the work area is adequately ventilated. When working on vehicles at ambient temperatures over 60 °C, all gas cylinders must be removed.	AS00.00-Z-0018-01A
24	Depressurize gas system.	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)
			AR47.10-P-0028NKB
25	Remove gas line from gas distribution rail.	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)
		 Bolt, gas rail to intake manifold	*BA07.54-P-1002-01C
26	Open mounting clamp of the gas line and remove gas line from the crankcase.	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)
27	Suction off refrigerant out of the air conditioning system.		AR83.30-P-1760NKB
28	Remove coolant hose (2).	 Hose clamp pliers	*003589033700
29	Remove coolant hose (3) from radiator (1) and transmission oil heat exchanger.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 724.0
		 Hose clamp pliers	*003589033700
30	Remove left charge air hose from charge air cooler (13) and set aside.		AR09.41-P-1311-01AL
31	Remove coolant hose (4).	 Hose clamp pliers	*003589033700
32	Remove right charge air hose (5) from charge air cooler (13) and set aside.		AR09.41-P-1311-01AL
33	Remove coolant hose (6) from cooler (1) and set aside.		AR20.20-P-7441-01RQ
34	Remove bleed line (8) from cooler (1) and coolant hose (9) and set bleed line (8) aside.		AR20.20-P-7441-01RQ
35	Remove refrigerant lines (10, 11) from condenser (12), set aside, and seal openings with suitable stop plugs.
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Replace sealing rings and moisten with compressor oil.
		 Bolt/nut, high-pressure line to condenser	*BA83.30-P-1014-01G
		 Bolt/nut, low-pressure line to condenser	*BA83.30-P-1015-01G
		 Record plug	*129589009100
36	Release and disconnect electrical connector from the fan unit (14) and set aside.		AR20.40-P-5050NKB
37.1	Detach vacuum hose from radiator shutters actuator and lay down on engine (25).	If installed.
			AR20.40-P-5050NKB
37.2	Disconnect electrical connector from radiator shutters actuator.	If installed.
			AR20.40-P-5050NKB
38	Remove complete radiator package together with the fan unit (14) upward.	 The radiator package consists of a cooler (1), condenser (12) and charge air cooler (13).
39	Remove bracket of the electric line B+ from radiator support (29) and remove radiator support (29) completely from front axle carrier and longitudinal members and take off.	 Bolt, radiator support to longitudinal member	*BA62.30-P-1001-04D
		 Bolt, connecting carrier to front axle carrier	*BA62.30-P-1004-04D
40	Release and disconnect electrical connectors from ME-SFI control unit (N3/10).
41	Remove air filter housing (15) together with the ME-SFI control unit (N3/10).		AR09.10-P-1150MT
42	Remove battery box (16).	 Bolt, battery bracket to body	*BA54.10-P-1001-01I
43	Disconnect engine wiring harness.		AR01.00-P-2410-02MT
		 Nut, circuit B+ to alternator	*BA15.40-P-1002-01F
		 Nut, connection for terminal designation 30	*BA15.30-P-1001-01J
44	Remove shift cable from shift module and transmission and set aside.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 711.6
			AR26.60-P-0635NKB
 Caution	Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid	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
45	Disconnect hydraulic line of the clutch operation from the clutch slave cylinder and seal openings with suitable stop plugs.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 711.6
Topical note	Brake fluid notes		AH42.50-P-0001-01A
		 Record plug	*129589009100
46	Remove purge line (17) from purging switchover valve, lay down on engine (25), and seal openings with suitable stop plugs.	 Record plug	*129589009100
47	Remove boost pressure control pressure transducer (Y77/1) from bulkhead and lay down with connected lines on the engine (25).	If boost pressure control pressure transducer (Y77/1) is installed on bulkhead.
			AR07.17-P-7002MT
48	Remove coolant hoses (18, 19) from bulkhead and unclip from the bracket.		AR20.20-P-7441-01RQ
49	Remove vacuum line (20) from vacuum pump and set aside.		AR43.10-P-0355NKB
50	Unclip coolant circulation pump (M13/5) from the bracket, disconnect electrical connector of the electric line (22), and lay down coolant circulation pump (M13/5) on the engine (25).	Engine 270 in model 117, 156, 176, 242, 246.2 with code 228 (Additional warm water heating) with code 581 (Automatic air conditioning)
51	Release and disconnect electrical connector from transmission oil cooling coolant circulation pump (M13/7) and set aside.	Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 724.0
52	Disconnect refrigerant line (23) from engine compartment separating point and seal openings with suitable stop plugs.
	Compressor oils (specification 362.1)		BB00.40-P-0362-01A
		 Installation: Replace sealing ring of refrigerant line (23) and wet with compressor oil.
		 Bolt/nut, low-pressure and high-pressure lines to expansion valve	*BA83.30-P-1002-01G
		 Record plug	*129589009100
53	Remove bottom engine stabilizer mount.		AR22.10-P-1130NKB
54	Position engine support frame (24) and secure engine (25) with tensioning strap (26) against falling down.		AR33.10-P-0105NKB
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Support fixture	*246589006200
55	Remove fuel line (27) from high-pressure pump and seal openings with suitable stop plugs.	 When removing fuel line (27), wear rubberized, oil-proof and fiber-free gloves and cover separating point with a suitable rag.
		 Pliers for click clamps	*171589003700
		 Record plug	*129589009100
		 Clamp	*000589403700
56	Remove screws from transmission mount on transmission.		AR26.10-P-0030NKB
		 Transmission mount remains at left longitudinal member.
57	Remove connecting strut and remove engine mount from engine (25).		AR22.10-P-1260-02NKB
		 Bolt, mounting console to cylinder head cover	*BA22.10-P-1001-01V
		 Bolt, torsion bar linkage at top to bearing dome	*BA22.10-P-1004-01V
		 Bolt, engine mount to engine (chain case cover or engine support)	*BA22.10-P-1005-01V
58	Move out engine (25) with transmission toward the front.
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Engine (25) may not be in contact with body panels or major assemblies. Otherwise damage will occur.
		 Installation: When installing engine (25), ensure that front separating point of exhaust system is located above front axle carrier.
		 Support fixture	*246589006200
59	Install in the reverse order.
	Check
60	Check oil level of the transmission and correct if necessary.	Only if transmission oil has leaked out.
		Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 724.0	AR27.00-P-0104NKB
		Engine 270 in model 117, 156, 176, 242, 246.2 with transmission 711.6	AR26.00-P-0200NKB
61	Check headlamp adjustment and correct if necessary.
			AP82.10-P-8260GI
62	Check leak tightness of the natural gas system while the engine (25) is running.	Engine 270 in model 242 with code 924 (Bivalent natural gas drive)
			AR07.54-P-0001NKB
 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
63	Perform engine test run; while doing so, check engine (25) and transmission for proper operation and leak tightness.

 Gas injection and ignition system

Number	Designation		Engine 270
BA07.54-P-1002-01C	Bolt, gas rail to intake manifold	Nm	9

 Starter

Number	Designation		Engine 270
BA15.30-P-1001-01J	Nut, connection for terminal designation 30	Nm	15

 Alternator

Number	Designation		Engine 270
BA15.40-P-1002-01F	Nut, circuit B+ to alternator	Nm	16