Remove/install engine with front axle carrier

AR01.10-P-2500OLD

Remove/install engine with front axle carrier

06.07.2020

Engine

651 in model 205 with transmission 725

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

1

Refrigerant lines

7

Air intake connection

10

Coolant hose

3

Electrical connector

8

Mounting clip

11

Coolant hose

6

Coolant vent line

9

Coolant hose

12

Vacuum line

16

Screw

18

Electrical line

B14

Outside temperature sensor

13

Nut

14

Condenser

15

Electrical connector

17

Refrigerant line

30

Bolts

31

Bracket

22

Screw

23

Ground cable

24

Fuel hose

25

Fuel hose

27

Diagonal strut

28

Diagonal strut

29

Steering coupling

32

Bolts

33

Front axle carrier

 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

 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 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

Topical note

Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

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

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

AH00.00-P-0015-01CW

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

AH01.10-P-0001-01A

Notes on automatic transmission

AH27.19-P-0001-01NKB

Notes on repair work on suspension components

AH00.00-P-0100-01A

Notes on AIRmatic

Engine 651 in model 205 with transmission 725
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AH32.22-P-1000-02LW

 

Remove/install

1

Secure vehicle against rolling away, shift transmission to neutral position, and release parking brake.

2

Deactivate easy entry and exit feature.

Engine 651 in model 205 with transmission 725
with code 275 (Driver's seat, electrically adjustable with memory function)
with code M005 (Vehicles with 4MATIC/all-wheel drive)



AD00.00-P-2000-04B

3

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

 Retainer device

*129589012100

4

Secure vehicle on vehicle lift.

AR00.60-P-0100CW

5

Relieve pressure from the air suspension with the diagnostic system.

Engine 651 in model 205 with transmission 725
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)



AD00.00-P-2000-04B

6

Discharge air conditioning system.

AR83.30-P-1760LW

7

Disconnect refrigerant lines (1) from the separating points and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation:
Use new sealing rings. Wet all threads and sealing rings with compressor oil.
Refrigerant can otherwise escape.

 Nut, refrigerant line to connecting point

*BA83.30-P-1004-01Q

 Record plug

*129589009100

8

Remove lower engine compartment paneling.

AR61.20-P-1105LW

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

9

Drain coolant at radiator.

AR20.00-P-1142LW

10

Drain coolant from low-temperature circuit.

AR09.41-P-6834LW

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

11

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

AR54.10-P-0003LW

12

Release and disconnect electrical connectors from the CDI control unit of the diesel injection system control unit (N3/9).

AR07.08-P-7008OLD

13

Remove air filter housing with CDI control unit of the diesel injection system control unit (N3/9).

AR09.10-P-1150OLD

14

Release and disconnect electrical connector (3) of the temperature sensor upstream of the diesel particulate filter (B19/9).

15

Remove engine wiring harness and place to one side.

AR15.18-P-1000-03OLD

 Nut, positive line to engine compartment prefuse box

*BA54.15-P-1003-01K

 Engine wiring harness ground connection to cylinder head cover

*BA00.19-P-1038-01E

16

Remove coolant vent line (6) from the expansion reservoir, cooler, and engine.

AR20.20-P-7441-01RQ

17

Remove low-temperature circuit expansion reservoir.

AR09.41-P-0001LWB

18

Remove air intake connection (7).

 Clip remover

*452589016300

19

Remove retaining clips (8) from the cooler.

20

Remove coolant hose (9) from the engine and seal with suitable stop plugs.

 Record plug

*129589009100

21

Remove coolant hose (10) from the cooler and seal with suitable stop plugs.

 Record plug

*129589009100

22

Remove coolant hose (11) from the firewall and seal with suitable stop plugs.

AR20.20-P-7441-01RQ

 Record plug

*129589009100

23

Remove vacuum line (12) and seal openings with suitable stop plugs.

 Record plug

*129589009100

24

Release and disconnect electrical connectors from the electric power steering actuator motor (A91m1) and unclip wiring harness of the electric power steering from the front axle carrier (33).

AR46.20-P-0600LW

25

Remove outside temperature sensor (B14).

26

Unclip cable strap of the electric line (18) from the bracket (31).

 Installation: Use new cable strap.

 Clip remover

*452589016300

27

Remove bolts (16).

28

Remove screws (30) and remove brackets (31) from the left and right damping.

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

29

Remove top coolant hose from the oil cooler.

AR27.55-P-1000LWX

30

Remove coolant hoses from the cooler and from the low-temperature circuit cooler.

AR20.20-P-3865LWB

31

Remove coolant hoses from the low-temperature circuit cooler.

AR09.41-P-6935OLD

32

Unclip oil cooler from the fan unit and secure against falling down with connected lines at the engine.

AR27.55-P-1000LWX

33

Remove heating circuit pump from the bracket of the front axle carrier (33) and fasten to the vehicle with connected lines.

AR83.25-P-1170LW

34

Remove SCR catalytic converter.

Engine 651 in model 205 with transmission 725
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code U77 (Diesel Emission control BLUETEC (SCR))

AR14.40-P-2006LWB

35

Relieve overpressure in the fuel tank by opening the fuel filler cap for a short time.

36

Mark fuel hoses (24, 25) relative to the fuel pipes.

37

Disconnect fuel hoses (24, 25) from the fuel pipes and seal openings with suitable stop plugs.

 Installation: Replace clamps.

 Installation: Observe markings.

 Pliers for click clamps

*171589003700

 Record plug

*129589009100

38

Remove propeller shaft from the output flange and secure on the vehicle against falling down.

AR41.10-P-0050LW

39

Release rear section of the front fender liner in the area of the diagonal struts (27, 28).

AR88.10-P-1300LW

40

Remove screws of the diagonal struts (27, 28) from the torsion bar bearing shells.

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

*BA61.10-P-1006-01L

41

Loosen screws of the diagonal struts (27, 28) from the longitudinal members and remove diagonal struts.

 Bolt, front diagonal strut to longitudinal member

*BA61.10-P-1007-01L

 Engine mount wrench set

*001589011600

42

Disconnect steering coupling (29) from the steering shaft.

AR46.10-P-8000LW

43

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

Engine 651 in model 205 with transmission 725
with code M005 (Vehicles with 4MATIC/all-wheel drive)1-piston floating caliper brake

AR42.10-P-0070LW

Engine 651 in model 205 with transmission 725
with code M005 (Vehicles with 4MATIC/all-wheel drive)4-piston fixed-caliper brake

AR42.10-P-0070LWA

Engine 651 in model 205 with transmission 725
with code B06 (Silver brake calipers)
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code B07 (AMG - ceramic brake system)
except code U70 (red-painted brake callipers)6-piston fixed-caliper brake

AR42.10-P-0070LWB

Engine 651 in model 205 with transmission 725
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code U70 (red-painted brake callipers)
except code B06 (Silver brake calipers)
except code B07 (AMG - ceramic brake system)6-piston fixed-caliper brake

AR42.10-P-0070LWD


Do not kink, crush or subject lines to tension.
This leads to line damage.

44

Release and disconnect electrical connector of the left active engine mount (Y123) and right active engine mount (Y123/1) in the front wheel well.

45

Unscrew screw (22) and remove ground line (23).

 Bolt, ground line to transmission housing

*BA27.10-P-1024-04H

46

Remove rpm sensors from steering knuckles.

AR42.30-P-0712LW

47

Unclip electric lines from the spring links and steering knuckles.

AR33.25-P-0400LW

48

Remove steering knuckles from the top transverse control arms.

AR33.25-P-0400LW


Secure steering knuckle.
Otherwise the joints will be damaged.

49

Detach suspension struts from spring links.

Engine 651 in model 205 with transmission 725
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 489 (AIRMATIC)

AR32.25-P-1017LW

Engine 651 in model 205 with transmission 725
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR32.25-P-1017LWL

50

Fasten radiator package to the reinforcement with a tensioning strap and secure against falling down.

 Commercially available devices/tools
Tensioning strap

51

Remove screws of the left and right bracket and remove bottom brackets of the radiator package from the damping.

 Bolt, soundproofing to front axle carrier

*BA62.30-P-1006-01H

52

Remove nut (13).

 Nut, line to condenser

*BA83.30-P-1002-01Q

53

Remove bottom refrigerant line (17) from the capacitor (14) and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation:
Use new sealing rings. Wet all threads and sealing rings with compressor oil.
Refrigerant can otherwise escape.

 Record plug

*129589009100

54

Release and disconnect electrical connector (15) of refrigerant pressure sensor (B12).

55

Support front axle carrier (33) and secure entire engine transmission unit against slipping and falling down with a tensioning strap.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

 Commercially available devices/tools
Tensioning strap

 Ensure even alignment of support plates.

56

Remove rear engine carrier from the frame floor assembly.

AR22.10-P-4360LWB

 The rear engine support remains on the transmission.

57

Remove screws (32) of the front axle carrier (33) from the longitudinal members.

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01Q

58

Remove heat shield from the transmission.

 Screw/bolt, heat shield to oil pan

*BA27.10-P-1009-04H

59

Release and disconnect electrical connector from the transmission.

60

Lower engine transmission unit with the front axle carrier (33) and radiator package.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B


Ensure that engine and its detachable parts are not in contact with body panels or major assemblies.
Do not kink, crush or subject lines to tension.
This leads to component and/or line damage.

 Aid of helper required.

61

Install in the reverse order.

Concluding tasks

62

Check engine oil level and correct if necessary.



AP18.00-P-1811MP

63

Correct transmission oil level.

AR27.00-P-0270EWN

64

Check engine cooling system for leak tightness.

AR20.00-P-1010LW

65

Check low-temperature circuit for leak tightness.

AR09.41-P-1010LW

66

Perform wheel alignment measurement.

AR40.20-P-0200LW

67

Read out and delete fault memory.



AD00.00-P-2000-04B

 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

68

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

69

Install lower engine compartment lining.

AR61.20-P-1105LW

70

Install upper engine cover.

 Ground points

Number

Designation

Model 205
up to model year 2019

Model 205
as of model year 2019

BA00.19-P-1038-01E

Engine wiring harness ground connection to cylinder head cover

Nm

9

9

 Automatic transmission complete

Number

Designation

Transmission 725.0/1

BA27.10-P-1009-04H

Screw/bolt, heat shield to oil pan

Nm

9

 Automatic transmission complete

Number

Designation

Transmission 725.0/1

BA27.10-P-1024-04H

Bolt, ground line to transmission housing

Nm

20

 Front axle carrier

Number

Designation

Model 205

BA33.10-P-1001-01Q

Bolt, front axle carrier to longitudinal member

Nm

180

 Fuse and relay box

Number

Designation

Model 205

BA54.15-P-1003-01K

Nut, positive line to engine compartment prefuse box

M6

Nm

8

M8

Nm

16

 Frame floor assembly

Number

Designation

Model 205

BA61.10-P-1006-01L

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

Nm

50

 Frame floor assembly

Number

Designation

Model 205

BA61.10-P-1007-01L

Bolt, front diagonal strut to longitudinal member

Nm

50

 Cross member and front reinforcement

Number

Designation

Model 205

BA62.30-P-1004-01H

Bolt, strut to soundproofing

M8

Nm

20

 Cross member and front reinforcement

Number

Designation

Model 205

BA62.30-P-1006-01H

Bolt, soundproofing to front axle carrier

M8

Nm

23

 Air conditioning

Number

Designation

Model 205

BA83.30-P-1002-01Q

Nut, line to condenser

Nm

12

 Air conditioning

Number

Designation

Model 205

BA83.30-P-1004-01Q

Nut, refrigerant line to connecting point

M6

Nm

12