Remove/install engine with front axle carrier

AR01.10-P-2500AK

Remove/install engine with front axle carrier

6.5.11

5.10.10

Method for lifting the vehicle changed; additional notes added.

Perform wheel alignment check - inserted.

Work steps 2 through 5

Step 60

 

Remove/install

 Danger!

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

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

AS00.00-Z-0010-01A

 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

 Installation

Replace self-locking nuts and bolts

1

Disconnect battery ground line

AR54.10-P-0003AK

2

Raise vehicle with vehicle lift

 Position arms of lifting platform such that fender liners (38) in front fenders can be removed.

AR00.60-P-1000AK

 Lift vehicle until wheel bearing is relieved of load in order to avoid damage to the wheel bearing.

3

Loosen bolt (1) or collar nut of left and right front axle shaft (49)

 Installation: To prevent damaging the wheel bearings, the torque of the bolt (1) or the collar nut must not be exceeded.

 If necessary (corrosion on collar nut and front axle shaft flange) a hub cap (see EPC) can be assembled.



*BA33.30-P-1001-07C



*BA33.30-P-1003-07C

4

Secure vehicle on vehicle lift

AR00.60-P-0100AK

5

Remove front wheels

 Turn if necessary.

AP40.10-P-4050AK

 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

6

Drain transmission oil

Only during repairs to the transmission.

AR27.00-P-0200-02AK

 Absolute cleanliness is essential when working on the transmission. Before opening the hydraulic system, thoroughly clean the area surrounding the separation point. Only lint-free cleaning cloths may be used. Even the smallest dirt particles in the hydraulic components can lead to malfunctions and a total failure of the transmission.

For repairs always wear oil-resistant, fiber-free gloves which are lined with rubber.

The transmission components should be stored in clean surroundings. Here we recommend covering the components or storing them in a clean plastic box with cover



*BA27.10-P-1001-03C

7

Drain coolant

AR20.00-P-1142AK

8

Remove front bumper.

On model 169.0/3

AR88.20-P-2000AK

9

Remove lower engine compartment paneling

With code (484) Rough road package

AR61.20-P-1105AL

without rough road package

AR61.20-P-1105AM

10

Unscrew bolt (2) from bracket (3) for engine wiring harness (4) at the ME-SFI [ME] control unit (N3/10)

11

Unlock and disconnect plug for engine wiring harness (4) and plug for vehicle wiring harness (5) at ME-SFI [ME] control unit (N3/10)

12

Loosen engine/engine compartment connector (X26/31) by turning out of air filter housing (7) and disconnect the engine/engine compartment connector (X26/31)

13

Remove air filter housing (7).

 Do not remove ME-SFI [ME] control unit (N3/10).

AR09.10-P-1050AK

14

Detach vacuum line for brake booster (8) at the intake manifold

15

Connect pressure hose at bleed valve (9) for the fuel distributor (10)

 This automatically reduces the fuel pressure.

 Collect escaping fuel in a suitable container.



*119589046300

16

Detach fuel line (11) at fuel distributor (10) and expose it at the firewall

 Seal fuel line (11) and fuel distributor (10) with suitable stoppers.

17

Detach vacuum line (12) at purge control valve and expose vacuum line (12)

18

Detach coolant hose (13) from radiator at thermostat housing

19

Detach coolant hose (14) from heat exchanger at thermostat housing

20

Detach coolant hose (15) from coolant pipe at radiator

21

Detach coolant hose (16) from heat exchanger at coolant pipe

22

Detach coolant hose (17) from coolant pipe at expansion reservoir

23

Secure radiator

AR20.20-P-3865-07AK



*169589004000

24

Unscrew nut (18) at right longitudinal frame member and place the ground line to the side



*BA15.10-P-1003-05B

25

Turn steering gear to center position

AR46.20-P-0500-01AK



*203589043103

26

Fix steering wheel in position using the retainer.

 The steering wheel must not be turned when the steering coupling is detached, otherwise the clock spring contact will be destroyed.



*129589012100

27

Unscrew bolt (19) from steering coupling (20) and detach steering coupling (20)

Disconnect if steering coupling (20) is not corroded.

AR46.10-P-8000-01AK



*BA46.10-P-1001-01H

Grease

*BR00.45-Z-1006-06A

Just disconnect a corroded steering coupling (20) for left-hand drive vehicles up to chassis end number 160000 for model 169 or chassis end number 008500 for model 245.

AR46.10-P-8000-01AL



*BA46.10-P-1001-01H



*203589023300

Body jig saw

gotis://K_58.1_01.0

Wet and dry vacuum cleaner

gotis://P_00.12_06.0

Grease

*BR00.45-Z-1006-06A

28

Replace steering gear

Only if steering shaft has been cut open because of a corroded steering coupling (20).

AR46.10-P-7300AK

29

Disconnect electrical connectors (22, 23) at steering and remove clip (21) with side cutting pliers

 If clip (21) is not removed properly, the cover of the torque sensor board (arrow) can get damaged. This can lead to ingress of moisture that can cause the steering to break down.

 Installation: Replace clip (21).

30

Unclip range selection cable (25) from ball head

AR27.60-P-0125-01AK

Long-life grease

*BR00.45-Z-1001-06A



Fastening range selection cable - altered

BT27.60-P-0020-01A

31

Unhook range selection cable (25) from bracket (26)

32

Unscrew bolt (27) and place the range selection cable (25) to the side



*BA27.10-P-1002-04D

33

Loosen oil hoses (28) from oil lines (29)

 Note installation position of the oil hoses (28), intercept the automatic transmission fluid in a suitable container, seal the oil hoses (28) and the oil lines (29) with suitable stoppers.

AR27.10-P-0501-03AK



*129589009100

34

Detach refrigerant compressor (A9) at the engine and fasten it on the vehicle underfloor with the connected refrigerant lines

In vehicles with code (580) Automatic air conditioning or with code
(581) Comfort automatic air conditioning

AR83.55-P-5300AK

35

Disconnect electrical connector (62) for left front level sensor (B22/8), unscrew the nut (61) and disengage linkage

For vehicles with code (614) Bi-xenon headlamp unit or code
(615) Bi-xenon headlamp unit with integrated curve illumination

36

Detach hose clamp (30) with a suitable tool and disconnect the exhaust system (31) at the connecting point from the exhaust manifold along with the catalytic converter (32)

 Installation: Replace the exhaust seal ring and check hose clamp (30); replace if necessary.

37

Unscrew bolt (33) and detach the ground line at oil pan



*BA01.45-P-1007-01O

38

Disconnect electrical connection (34) and unclip retaining clip (35)

39

Remove bolt (40) and the plastic nuts (39) from left and right fender liner (38)

40

Remove clips (41) from the fender liner (38) on left and right and fold down both fender liners (38)

41

Detach left and right connecting rod (42) from stabilizer (43)



*BA32.20-P-1002-02K

42

Remove bolts on the left and right stabilizer bar bearing shell (44) and remove the stabilizer bar bearing shell (44)

 Check rubber mount and replace if necessary.



*BA32.20-P-1001-02K

43

Unscrew nut (45) on tie rod end (46) on the left and on the right and press the tie rod end (46) on the left and on the right out of steering knuckle

 Press out tie rod end (46) to avoid damaging the rubber boots.

 Installation: Check rubber boots; replace tie rod end (46) if necessary.



*BA46.40-P-1001-01J



*171589003400



*601589043300

44

Unscrew nuts (47) for left and right flange joint (48)



*BA33.25-P-1001-01E

45

Unscrew bolt (1) or collar nut of left and right front axle shaft (49)

 Replace bolts (1) and collar nuts.

 Installation: Screw in bolts (1) and collar nuts up to the stop.

46

Loosen flange joints (48) on the left and right from steering knuckle and remove

 Carefully press out the flange joints (48) so that there is no damage to the rubber boots.

Place rags between the transverse control arm and front axle carrier (51) so that there is no damage.

 Check rubber boots; replace flange joints (48) if necessary.

 Installation: If the corrosion protection layer is damaged at the time of pressing down the transverse control arm it must be repaired with preservation agent.



*203589003300



*129589106300

Preservation agent

*BR00.45-Z-1003-05A

47

Pull left and right front axle shaft (49) out of wheel hub.

48

Mount engine hoist and raise engine slightly

Engine supporting device, engine lifting device

gotis://A_01_09.0

49

Remove screws/bolts (52)

 Installation: First fit all the bolts (52), then tighten.



*BA33.10-P-1001-01G

50

Carefully lower engine with the front axle carrier (51) using the engine hoist until the starter (M1) and alternator (G2) are accessible

 When lowering check for unobstructed movement of coolant hoses, air-conditioning lines and electric lines, in order to avoid causing any damage.

 Aid of helper required.

51

Unscrew wiring harness bracket (53) at the lifting eye (54) and detach the retaining clips (55)

52

Detach electrical connector (56) at alternator (G2)

 Installation: Ensure that electrical connector (56) is seated correctly.

53

Unscrew protection against accidental contact (57), unscrew nut (58) and remove electrical line (59)



*BA15.40-P-1002-01K

54

Detach wiring harness (60) at starter (M1)



*BA15.30-P-1002-01L



*BA15.30-P-1003-01L

55

Support engine and front axle carrier (51)



*169589016200

Major assembly lifting platform / scissors-type pallet forklift with a universal mount

gotis://A_01_07.1

56

Carefully lower engine further with front axle carrier (51)

 When lowering check for unobstructed movement of coolant hoses, air-conditioning hoses and electric lines, in order to avoid causing any damage.

 Aid of 2 helpers required.

57

Install in the reverse order

58

Inspect cooling system for leaks

AR20.00-P-1010AK

59

Check oil level in automatic transmission and correct if necessary.

AR27.00-P-0100AK

60

Perform wheel alignment check

AR40.20-P-0200AK

61

Check headlamp adjustment and if necessary correct

On vehicles with code (614) Bi-xenon headlamp unit or code (615) Bi-xenon headlamp unit with integrated curve illumination

AP82.10-P-8260AK

Number

Designation

Engine
266

BA01.45-P-1007-01O

Bolt, ground line to oil pan

Nm

20

Number

Designation

Engine
266

BA15.10-P-1003-05B

Bolt, ground strap to the right longitudinal member

Nm

9

Number

Designation

Engine
266

BA15.30-P-1002-01L

Nut for circuit 30 (positive battery terminal)

Nm

14

BA15.30-P-1003-01L

Nut for circuit 50

Nm

6

Number

Designation

Engine
266

BA15.40-P-1002-01K

Cable on alternator terminal B+

Nm

18

Number

Designation

Trans-missions
722.800/
801

BA27.10-P-1001-03C

Oil drain screw to oil pan

Nm

22

Number

Designation

Trans-missions
722.800/
801

BA27.10-P-1002-04D

Bolt, range selector cable bracket to transmission

Nm

8

Number

Designation

Model
169

Model
245

BA32.20-P-1001-02K

Bolt, torsion bar to front axle carrier

Nm

28

28

BA32.20-P-1002-02K

Self-locking nut, connecting rod to torsion bar

Nm

60

60

Number

Designation

Model
169

Model
245

BA33.10-P-1001-01G

Bolt, front-axle carrier to body

M10

Nm

-

-

M12

Nm

130

130

Number

Designation

Model
169

Model
245

BA33.25-P-1001-01E

Nut, flange ball joint of transverse control arm to steering knuckle

Stage 1

Nm

50

50

Stage 2

°

60

60

Number

Designation

Model 169

Model 245

BA33.30-P-1001-07C

Bolt, drive shaft to front axle shaft flange

Stage 1

Nm

80

80

Stage 2

°

90

90

BA33.30-P-1003-07C

Collar nut with sub head toothing, axle shaft to front axle shaft flange

Stage 1

Nm

100

100

Stage 2

°

60

60

Number

Designation

Model
169

Model
245

BA46.10-P-1001-01H

Clamp screw, steering coupling to rack-and-pinion steering

Nm

20

20

Number

Designation

Model
169

Model
245

BA46.40-P-1001-01J

Self-locking nut, tie rod to steering knuckle

Nm

60

60

Number

Designation

Order number

BR00.45-Z-1003-05A

Cavity sealant, solvent-free (1 l container)

A 000 986 72 70 05

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11

BR00.45-Z-1006-06A

Anti-corrosion grease 40 g / DB supply specification 6834.00

A 001 989 37 51 10