Remove/install engine with front axle carrier

AR01.10-P-2500OLC

Remove/install engine with front axle carrier

17.08.2020

Engine

654 in model 213, 238

with code M005 (Vehicles with 4MATIC/all-wheel drive)

Modification notes

28.05.2020

Bolt, strut to soundproofing

Model 213

BA62.30-P-1004-01H

01.07.2020

Hybrid variant incorporated.

Shown on model 213

1

Coolant hose

2

Vacuum line

3

Vacuum line

4

Refrigerant line

5

Refrigerant line

6

Separation point

7

Coolant hose

8

Reinforcement

9

Vent line

10

Injection line

11

Coolant hose

Shown on model 213

15

Strut

19

Fuel hoses

B12

Refrigerant pressure sensor

17

Coolant hose

20

Fuel lines

M13/5

Coolant circulation pump

18

Electric power steering actuator motor

22

Diagonal strut

Shown on model 213.011/211

40

High-voltage plug

44

High-voltage plug

41

Shield

45

Electrical connector

42

Cable duct of high voltage lines

47

High-voltage line

43

Equipotential bonding line

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AS00.00-Z-0035-01A

 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

 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

 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

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AH00.00-Z-0300-01A

Topical note

Notes on AIR BODY CONTROL

Engine 654 in model 238
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AH32.22-P-1000-03LWO

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-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

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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

AH01.10-P-0001-01A

Notes on AIRmatic

Model 213 with engine 654
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AH32.22-P-1000-02LW

 

Remove/install

1

Secure vehicle on vehicle lift.

AR00.60-P-1006A

2

Connect vehicle diagnosis system and relieve pressure in AIRMATIC system.



Engine 654 in model 238
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-06LWO



Engine 654 in model 213
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-04B

3

Perform power disconnect of high-voltage on-board electrical system.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR54.10-P-1150LHV

4

Put transmission into neutral position.

5

Release parking brake.

6

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


Do not turn steering wheel with steering coupling removed.
Clock spring contact will otherwise be destroyed.

 Retainer device

*129589012100

7

Disconnect ground line of on-board electrical system battery (G1).

Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR54.10-P-0003LWO

Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR54.10-P-0003LW

8

Remove lower engine compartment paneling.

AR61.20-P-1105LWE

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

9

Drain off coolant.

AR20.00-P-1142OLC

10

Discharge air conditioning system.

Model 238 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR83.30-P-1760LWO

Model 213 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 1U6 (R744 refrigerant)

AR83.30-P-1760LW

11

Remove air filter housing.

AR09.10-P-1150OLC

12

Remove coolant hose (1) from firewall.

AR20.20-P-7441-01RQ

13

Remove vacuum line (2) from vacuum line (3).

14

Disconnect refrigerant lines (4, 5) from separating point (6) and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing rings and moisten with compressor oil.

 Nut/bolt, connecting point for refrigerant line

*BA83.30-P-1004-01R

 Assembly tool

*000589936300

 Record plug

*129589009100

15

Disconnect engine wiring harness for removal of the engine.

AR15.18-P-1000-05OLC

 Engine 654 in model 213 with transmission 725.0
with code M005 (Vehicles with 4MATIC/all-wheel drive)Screw/bolt, heat shield to oil pan

*BA27.10-P-1009-04H

 Nut, positive line to busbar on firewall

*BA54.18-P-1001-02C

 Model 238 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)Bolt/nut, ground line to transmission/underfloor

*BA00.19-P-1039-02B

 Model 213 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)Screw/bolt/nut, ground line to transmission/underfloor

*BA00.19-P-1038-02A

16

Remove the coolant expansion reservoir.

AR20.30-P-4949OLC

17

Remove reinforcement (8).

 M81

*BA00.10-P-1004-04A

 M61

*BA00.10-P-1002-04A

 Bolt, lock striker to cross member/front-module carrier

*BA62.30-P-1008-01H

18

Remove coolant hose (7) at low-temperature circuit cooler and seal openings with protective covers.

Engine 654 in model 213 (except 213.011/211), 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

19

Remove refrigerant line (5) from condenser and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring and moisten with compressor oil.

 Nut/bolt, refrigerant line to condenser

*BA83.30-P-1006-01R

 Assembly tool

*000589936300

 Record plug

*129589009100

20

Release and disconnect electrical connection from fan unit.

21

Fix bleed line (9) in place on engine.

22

Remove injection line (10) of the exhaust gas aftertreatment system from the injection nozzle.

AR14.40-P-2000OLC

23

Lay down coolant hose (11) on engine.

24

Release and disconnect electrical connector (45) and high-voltage plug (44) from electric refrigerant compressor (A9/5).

Engine 654.9 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

AR83.55-P-5311OLQ

25

Remove high voltage line (47) from charge-air distributor.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

26

Release and disconnect electrical connector from refrigerant pressure sensor (B12).

27

Remove struts (15) from damping.

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

28

Release and disconnect electrical connector from low-temperature circuit temperature sensor.

AR09.41-P-6925OLC

29

Remove coolant lines from low-temperature circuit circulation pump and seal openings with clean protective covers.

AR09.41-P-6925OLC

 Set of protective covers

*001589019100

30

Release and disconnect electrical connector from coolant circulation pump (M13/5).

31

Remove coolant hose (17) from coolant circulation pump (M13/5) and seal openings with protective covers.

 Hose clamp pliers

*454589003700

 Set of protective covers

*001589019100

32

Release and disconnect electrical connectors from electric power steering actuator motor (18).

33

Unclip wiring harness of electric power steering from front axle carrier.

34

Remove fuel hoses (19) from fuel lines(20) and collect escaping fuel in a suitable vessel.

 Installation: Install new fuel hoses (19).

 Pliers for click clamps

*171589003700

35

Seal connections of the fuel hoses (19) and fuel lines (20) with suitable stop plugs.

 Record plug

*129589009100

36

Release and disconnect high-voltage plug from high voltage PTC heater (N33/5).

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR83.70-P-8001LHW

37

Remove equipotential bonding line (43) from transmission.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Nut/bolt, equipotential bonding line to high-voltage distributor/transmission

*BA54.10-P-1004-03F

38

Remove high-voltage distributor and place to one side with connected high-voltage lines.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Nut, high-voltage distributor to high-voltage distributor bracket

*BA54.10-P-1002-03F

39

Remove propeller shaft from transmission output flange.

AR41.10-P-0050LW

40

Remove front diagonal strut.

Engine 654 in model 238.4
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR61.10-P-5144LWO

41

Remove diagonal struts (22).

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

AH00.00-P-0015-01CW

 Bolt, front diagonal strut to front axle carrier/torsion bar bearing shell/radiator mounting console

*BA61.10-P-1006-01L

 Bolt, front diagonal strut to longitudinal member

*BA61.10-P-1007-01L

 Engine mount wrench set

*001589011600

42

Remove steering coupling from steering shaft.

Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR46.10-P-8000LWO

Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR46.10-P-8000LW

43

Remove left and right front-axle rpm sensors (L6/1, L6/2) from steering knuckles.

Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR42.30-P-0713LWO

Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR42.30-P-0712LW

44

Unclip electric lines of the spring links and steering knuckles.

45

Remove brake calipers with the brake caliper supports and fasten to the vehicle free of tension.

Model 213 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR42.10-P-0070LW

Model 238 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR42.10-P-0070LWO

46

Remove steering knuckles from top transverse control arms.

Model 238 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR33.25-P-0400LWQ

Model 213 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR33.25-P-0400LW


Secure the steering knuckle again folding away.
Otherwise the joints will be damaged.

47

Detach suspension struts from spring links.

Model 238 with engine 654
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR32.25-P-1017LWQ

Model 238 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 489 (AIR BODY CONTROL)

AR32.25-P-1017LWO

Model 213 with engine 654
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR32.25-P-1017LWL

Model 213 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 489 (AIRMATIC)

AR32.25-P-1017LW

48

Support front axle carrier with lifting platform.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

49

Secure engine transmission unit and radiator package with tensioning strap against slipping and falling down.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

50

Remove rear engine carrier from frame floor assembly.

AR22.10-P-4360OLC

 The rear engine support remains on the transmission.

51

Remove screws of the front axle carrier from the longitudinal member.

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01Q

52.1

Lower engine transmission unit with front axle carrier and radiator package.

Engine 654 in model 213 (except 213.011/211), 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with front axle carrier and radiator package
Otherwise damage will occur.

 Aid of helper required.

52.2

Carefully lower engine transmission unit with front-axle carrier and radiator package until high-voltage plug (40) is accessible.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with front axle carrier and radiator package
Otherwise damage will occur.

 Aid of helper required.

53

Remove cable duct of high voltage lines (42) from transmission.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Bolt, 3-phase high-voltage line cable duct to transmission

*BA08.10-P-1003-01H

 Bolt, 3-phase high-voltage line protective hoop/cable duct to transmission

*BA08.10-P-1002-01H

54

Remove shield (41) over high-voltage plug(40).

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)

55

Remove high-voltage plug (40) of electric machine, place cable duct of high voltage lines (42) to one side and seal connections with protective covers.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)


Cover up high-voltage connector (40) and handle carefully.
Otherwise the high-voltage on-board electrical system may be damaged.

 Bolt, 3-phase high-voltage line connecting plug to transmission

*BA08.10-P-1001-01H

 Set of protective caps

*001589029100

56

Lower engine transmission unit with front axle carrier and radiator package.

Engine 654 in model 213.011/211
with code M005 (Vehicles with 4MATIC/all-wheel drive)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with front axle carrier and radiator package
Otherwise damage will occur.

 Aid of helper required.

57

Fasten steering knuckles with a tensioning strap to the engine.

58

Install in the reverse order.

Concluding tasks

59

Perform wheel alignment measurement.

Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR40.20-P-0200LWO

Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR40.20-P-0200LW

60

Read out and delete fault memory.



Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-06LWO



Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-04B

61

Calibrate Distance Pilot DISTRONIC controller unit.



Engine 654 in model 213
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-04B



Engine 654 in model 238
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AD00.00-P-2000-06LWO

62

Check engine oil level and correct if necessary.



AP18.00-P-1812MKI

 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 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

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

Number

Designation

8.8

10.9

BA00.10-P-1004-04A

M81

Nm

23

33

 Ground points

Number

Designation

Model 213

BA00.19-P-1038-02A

Screw/bolt/nut, ground line to transmission/underfloor

M8

Nm

20

 Ground points

Number

Designation

Model 238

BA00.19-P-1039-02B

Bolt/nut, ground line to transmission/underfloor

M8

Nm

20

 Electric motor

Number

Designation

Model 213.011/016/050/053/054/153/155/211/216/253

BA08.10-P-1001-01H

Bolt, 3-phase high-voltage line connecting plug to transmission

Nm

10

 Electric motor

Number

Designation

Model 213.011/016/050/053/054/153/155/211/216/253

BA08.10-P-1002-01H

Bolt, 3-phase high-voltage line protective hoop/cable duct to transmission

Nm

9

 Electric motor

Number

Designation

Model 213.011/016/050/053/054/153/155/211/216/253

BA08.10-P-1003-01H

Bolt, 3-phase high-voltage line cable duct to transmission

Nm

5

 Automatic transmission complete

Number

Designation

Transmission 725.0/1

BA27.10-P-1009-04H

Screw/bolt, heat shield to oil pan

Nm

9

 Front axle carrier

Number

Designation

Model 213

Model 238

BA33.10-P-1001-01Q

Bolt, front axle carrier to longitudinal member

Nm

180

180

 High-voltage distributor

Number

Designation

Model 213.011/016/050/053/054/153/155/211/216/253

BA54.10-P-1002-03F

Nut, high-voltage distributor to high-voltage distributor bracket

Nm

6

 High-voltage distributor

Number

Designation

Model 213.011/016/050/053/054/153/155/211/216/253

BA54.10-P-1004-03F

Nut/bolt, equipotential bonding line to high-voltage distributor/transmission

M6

Nm

9

M8

Nm

20

 Wiring harness

Number

Designation

Model 213

Model 238

BA54.18-P-1001-02C

Nut, positive line to busbar on firewall

M6

Nm

8

8

M8

Nm

16

16

 Frame floor assembly

Number

Designation

Model 213

Model 238

BA61.10-P-1006-01L

Bolt, front diagonal strut to front axle carrier/torsion bar bearing shell/radiator mounting console

Nm

50

50

 Frame floor assembly

Number

Designation

Model 213

Model 238

BA61.10-P-1007-01L

Bolt, front diagonal strut to longitudinal member

Nm

50

50

 Cross member and front reinforcement

Number

Designation

Model 213

Model 238

BA62.30-P-1004-01H

Bolt, strut to soundproofing

M8

Nm

20

23

 Cross member and front reinforcement

Number

Designation

Model 213

Model 238

BA62.30-P-1008-01H

Bolt, lock striker to cross member/front-module carrier

Nm

10

10

 Air conditioning

Number

Designation

Model 213
except code 1U6 (R744 refrigerant)

Model 238

BA83.30-P-1004-01R

Nut/bolt, connecting point for refrigerant line

Nm

12

12

 Air conditioning

Number

Designation

Model 213
except code 1U6 (R744 refrigerant)

Model 238

BA83.30-P-1006-01R

Nut/bolt, refrigerant line to condenser

Nm

12

12