Remove/install engine with front axle carrier

AR01.10-P-2500MRT

Remove/install engine with front axle carrier

08.10.2019

Engine

256.9 in model 222

Modification notes

14.06.2016

Schraube Versteifung an Stirnwand/Längsträger/Versteifung Mitte

BA62.25-P-1001-01B

1

Electrical connector

7

Coolant hose

13

Vacuum line

2

Electrical connector

8

Coolant hose

14

Coolant hose

3

Fuel hose

9

Coolant hose

A

Vent line

4

Purge line

10

Vent line

B

Coolant hose

5

Coolant hose

11

Electrical connector

N3/10

ME-SFI [ME] control unit

18

Electrical line

21

Coolant hose

27

Coolant hose

19

Coolant hose

22

Coolant hose

23

Nut

20

Coolant hose

24

Coolant hose

25

Bolts

26

Bracket

M43/6

Low temperature circuit circulation pump 1

Y73/1

Low-temperature circuit switchover valve

30

Partition wall

35

Electrical line

31

Line routing

36

Electrical connectors

32

Reinforcement

37

Electrical line

33

Screw

F153/2

Engine compartment 48 V on-board electrical system fuse box

34

Electrical line

 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

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-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

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 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

 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

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

Notes on AIRmatic

Engine 256.9 in model 222
except code 487 (Active Body Control (ABC))

AH32.22-P-1000-02LF

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

AH01.10-P-0001-01A

Notes on repair work on suspension components

AH00.00-P-0100-01A

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

AH00.00-P-0015-01CW

 

Remove/install

1

Deactivate easy entry and exit feature.

2

Move transmission to neutral position and release the parking brake.

3

Secure vehicle on vehicle lift.

AR00.60-P-0100CW

4

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

 Retainer device

*129589012100

5

Release screws of front axle shafts.

Engine 256.9 in model 222
with code M005 (Vehicles with 4MATIC/all-wheel drive)
When engine is removed from front axle carrier.

 Aid of helper required.

 Screw/bolt, front axle shaft to wheel hub

*BA33.30-P-1001-02H

6

Remove front wheel and tire assemblies.

AR40.10-P-1102A

7

Release pressure in AIRMATIC system using vehicle diagnosis system.



AD00.00-P-2000-04B

8

Discharge air conditioning system.

AR83.30-P-1760LF

9

Disconnect ground line from battery.

AR54.10-P-0003LF

10

Remove air filter housing.

AR09.10-P-1150MRT

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

11

Drain coolant from low-temperature circuit.

AR09.41-P-6834MRT

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

12

Drain off coolant.

AR20.00-P-1142MRT

13

Release and disconnect electrical connectors (1, 2) and unclip electrical wiring harness.

14

Remove purge line (4) from purge control valve and seal openings with suitable stop plugs.

 Record plug

*129589009100

15

Remove vacuum line (13) from bulkhead and seal openings with suitable stop plugs.

 Record plug

*129589009100

16

Remove coolant hose (14) from bulkhead and seal openings using suitable protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

17

Release and connect inerting system line at bulkhead.

Engine 256 in model 222
with code 2U8 (Alternative refrigerant)

AR86.10-P-0419LF

18

Release and disconnect electrical connectors of switchable engine mounts and unclip lines.

AR22.10-P-4330MRT

19

Remove fuel pressure via the service connection.

AR07.03-P-1460-01MUB

 Cap on service connection

*BA07.03-P-1009-01MRT

 Pressure hose

*119589046300

20

Remove fuel hose (3) from service connection and seal openings with suitable stop plugs.

 Union nut, fuel hose to diagnostic socket

*BA07.03-P-1010-01MRT

 Engine mount wrench set

*001589011600

 Record plug

*129589009100

21

Remove coolant hose (5) from connection fitting of coolant thermostat and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

22

Remove refrigerant lines from refrigerant compressor and seal openings with suitable stop plugs.

AR83.55-P-5310MRT

 Record plug

*129589009100

23

Release and disconnect electrical connector at refrigerant compressor.

AR83.55-P-5310MRT

24

Remove bleed line (10) from cylinder head and seal openings with suitable stop plugs.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

25

Remove coolant hose (8) and coolant hose (9) from coolant pump and seal openings using suitable protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

26

Remove coolant hose (7) from coolant pipe and seal openings using suitable protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

27

Release and disconnect electrical connector (11) at bracket.

28

Remove bleed line (A) and seal openings with suitable stop plugs.

 Record plug

*129589009100

29

Remove coolant hose (B) from charge-air distributor and seal openings using suitable protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

30

Remove cover above right suspension strut tower.

31

Remove partition (30).

 M61

*BA00.10-P-1002-04A

32

Remove line routing (31) and place to one side.

33

Remove reinforcement (32).

 Bolt, reinforcement to firewall/longitudinal member/reinforcement, center

*BA62.25-P-1001-01B

 Bolt, reinforcement to suspension strut support

*BA62.25-P-1002-01B

34

Remove electric line (34).

 Nut, positive terminal to engine compartment prefuse box

*BA54.15-P-1002-01J

35

Remove electric line (37).

 Nut, positive terminal (F153/2) to fuse box for 48 V on-board electrical system in engine compartment

*BA54.15-P-1008-01J

36

Remove electric line (35) from body.

 Right front suspension strut tower ground point

*BA00.19-P-1028-01C

37

Unclip engine compartment 48 V on-board electrical system fuse box (F153/2).

38

Release and disconnect electrical connectors (36).

39

Remove screw (33) and unclip wiring harness at firewall.

40

Place engine compartment 48 V on-board electrical system fuse box (F153/2) with connected wiring harness on engine and secure against falling down.

41

Remove gasoline particulate filter.

AR49.20-P-0016MRT

42

Release and disconnect electrical connectors at rack-and-pinion steering and unclip electric line (18) from front axle carrier and place to one side.

AR46.20-P-0600LF

43

Disconnect steering coupling at steering shaft.

Engine 256.9 in model 222 as of 4/30/14

AR46.10-P-8000-01LW


Do not turn steering wheel when steering coupling is disconnected.
Clock spring contact will otherwise be damaged.

 Engine mount wrench set

*001589011600

44

Release left front wheel arch liner in rear area.

AR88.10-P-1300LF

45

Remove coolant hoses (21, 22) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

46

Unscrew nut (23).

47

Remove coolant hose (24) from low-temperature circuit switchover valve (Y73/1) and seal openings using suitable protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

48

Remove screws (25) and secure bracket (26) with low-temperature circuit circulation pump 1 (M43/6) against falling down.

 Bolt, holder for coolant pump/valve to body

*BA20.10-P-1003-01MRT

49

Release and disconnect outside temperature sensor electrical connector and unclip wiring harness and place to one side.

50

Remove coolant hoses (19, 20) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

51

Remove coolant hose (27) from coolant return flow line of automatic transmission oil cooler and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

52

Remove heat shield from transmission.

AR27.40-P-0700-01LF

 Screw/bolt, heat shield to oil pan

*BA27.10-P-1009-04H

53

Release and disconnect electrical connector at transmission and unclip electrical wiring harness.

54

Unscrew ground line of transmission at body.

 Bolt/nut, ground line to transmission/underfloor

*BA00.19-P-1039-01C

55

Release and disconnect electrical connector of brake wear indicator and remove from brake caliper.

 M61

*BA00.10-P-1002-04A

56

Remove rpm sensors from steering knuckles.

AR42.30-P-0712LF

57

Remove line routing on right and left at integral carrier.

58

Unclip electric lines from spring links and steering knuckles and secure in wheel well.

59

Remove brake calipers with brakepads and attach to the vehicle with the brake hose attached and free of tension.

AR42.10-P-0070LF

60

Remove spring struts from spring link.

Engine 256.9 in model 222
except code 487 (Active Body Control (ABC))

AR32.25-P-1017LFB

61

Remove upper transverse control arm from steering knuckles and secure against folding down.

AR33.20-P-0500LF

62

Detach drive shaft from transmission.

AR41.10-P-0050LF

63

Secure coolers against falling down.

64

Support front axle carrier with lifting platform and major assembly mount and secure entire engine transmission unit using a tensioning strap against slipping and falling down.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 When doing so ensure that mounting plates are evenly aligned.

65

Remove rear engine carrier from frame floor assembly.

AR22.10-P-4360MRT

66

Remove screws of rear mounting supports at longitudinal members.

 Bolt, rear mounting console to longitudinal member

*BA33.10-P-1005-01P

67

Remove screws of front axle carrier.


Never use impact wrench/driver or compressed air tools for screwing in or unscrewing the screw/bolts.
Thread will otherwise be damaged.

 Installation: Replace screw/bolts.

 Screw/bolt, front axle carrier at rear to longitudinal member

*BA33.10-P-1002-01P

 Screw/bolt, front axle carrier at front to longitudinal member

*BA33.10-P-1001-01P

68

Lower engine transmission unit with front axle carrier.

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

 Aid of helper required.

69

Install in the reverse order.



Check

70

Check engine oil level and correct.



AP18.00-P-1812SKI

71

Read out and delete fault memory.



AD00.00-P-2000-04B

72

Perform chassis alignment.

AR40.20-P-0200LF

 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

73

Carry out engine test run and check engine for proper leaktightness and leaktightness.

74

Install lower engine compartment paneling.

AR61.20-P-1105LF

75

Install upper engine cover.

AR01.10-P-2405MRT

 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 222
up to model year 2018

Model 222
as of model year 2018

BA00.19-P-1028-01C

Right front suspension strut tower ground point

W35/1

Nm

7

7

 Ground points

Number

Designation

Model 222
up to model year 2018

Model 222
as of model year 2018

BA00.19-P-1039-01C

Bolt/nut, ground line to transmission/underfloor

M8

Nm

20

20

 High-pressure line, low-pressure line, fuel distributor

Number

Designation

Engine 256.9

BA07.03-P-1009-01MRT

Cap on service connection

Plastic

Nm

1

 High-pressure line, low-pressure line, fuel distributor

Number

Designation

Engine 256.9

BA07.03-P-1010-01MRT

Union nut, fuel hose to diagnostic socket

Nm

24

 Coolant thermostat, coolant pump

Number

Designation

Engine 256

BA20.10-P-1003-01MRT

Bolt, holder for coolant pump/valve to body

Nm

20

 Automatic transmission complete

Number

Designation

Transmission 725.0

BA27.10-P-1009-04H

Screw/bolt, heat shield to oil pan

Nm

9

 Front axle carrier

Number

Designation

MODEL 222 except CODE Z07

MODEL 222 with CODE Z07

BA33.10-P-1001-01P

Screw/bolt, front axle carrier at front to longitudinal member

Stage 1

Nm

140

100

Stage 2

Loosen

°

–

–180

Stage 3

Nm

–

140

Stage 4

°

–

45

 Front axle carrier

Number

Designation

MODEL 222 except CODE Z07

MODEL 222 with CODE Z07

BA33.10-P-1002-01P

Screw/bolt, front axle carrier at rear to longitudinal member

Stage 1

Nm

70

100

Stage 2

Loosen

°

–

–180

Stage 3

Nm

–

140

 Front axle carrier

Number

Designation

MODEL 222 except CODE Z07

MODEL 222 with CODE Z07

BA33.10-P-1005-01P

Bolt, rear mounting console to longitudinal member

Nm

50

50

 Front axle shaft

Number

Designation

Model 222

BA33.30-P-1001-02H

Screw/bolt, front axle shaft to wheel hub

Stage 1

Nm

160

Stage 2

loosen approx. 90°

Stage 3

Nm

220

Stage 4

°

45

 Fuse and relay box

Number

Designation

Model 222

BA54.15-P-1002-01J

Nut, positive terminal to engine compartment prefuse box

M6

Nm

8

M8

Nm

16

 Fuse and relay box

Number

Designation

Model 222

BA54.15-P-1008-01J

Nut, positive terminal (F153/2) to fuse box for 48 V on-board electrical system in engine compartment

M8

Nm

16

 Firewall

Number

Designation

Model 222

BA62.25-P-1001-01B

Bolt, reinforcement to firewall/longitudinal member/reinforcement, center

M6

Nm

9

M8

Nm

30

 Firewall

Number

Designation

Model 222

BA62.25-P-1002-01B

Bolt, reinforcement to suspension strut support

M8

Nm

30