Remove/install engine with front axle carrier

AR01.10-P-2500OLE

Remove/install engine with front axle carrier

14.03.2018

Engine

651 in model 205 with transmission 722.96

Modification notes

12.07.2017

Operation steps added and method revised

Operation steps 1 to 70.

1

Refrigerant lines

7

Cold air intake

2

Differential pressure sensor (DPF)

8

Retaining clips

3

Electrical connector

9

Coolant hose

4

Bracket

10

Coolant hose

5

Electrical wiring harness

11

Coolant hose

6

Coolant vent line

12

Vacuum line

Shown on model 205 (except 205.4)

13

Electrical connector

18

Bracket

14

Lower air duct segment

19

Bracket

15

Refrigerant pressure sensor

20

Low-temperature circuit temperature sensor

16

Strut

21

Low-temperature circuit circulation pump

17

Strut

Shown on model 205 (except 205.4)

22

Screw

23

Ground cable

24

Fuel hose

25

Fuel hose

26

Heat shield

27

Diagonal strut

28

Diagonal strut

29

Steering coupling

Shown on model 205.4

30

Diagonal struts

31

Trim Panels

 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 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

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 722.96
with code 489 (AIRMATIC)

AH32.22-P-1000-02LW

 

Remove/install

1

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

2

Turn wheels on front axle to straight-ahead position and secure steering wheel with holding device

 Retainer device

*129589012100

3

Deactivate easy entry/exit feature

Engine 651 in model 205 with transmission 722.96
with code 275 (Memory package)

4

Secure vehicle on vehicle lift

AR00.60-P-0100CW

5

Fully depressurize AIRMATIC system with vehicle diagnosis system

Engine 651 in model 205 with transmission 722.96
with code 489 (AIRMATIC)



AD00.00-P-2000-04B

6

Drain air conditioning system

AR83.30-P-1760LW

7

Disconnect refrigerant lines (1) at connecting points and close off openings with a suitable stop plug



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 from low-temperature circuit

AR09.41-P-6834LW

10

Drain coolant at radiator

AR20.00-P-1142LW

11

Disconnect battery ground line

AR54.10-P-0003LW

12

Remove air filter housing

AR09.10-P-1150OLD

13

Release and disconnect electrical connection on DPF differential pressure sensor (2)

14

Release and disconnect electrical connector (3) of temperature sensor upstream of diesel particulate filter

15

Disconnect engine wiring harness to remove engine and place to one side

AR15.18-P-1000-03OLD

16

Remove bracket (4) together with electrical wiring harness (5) from rear right engine lifting lug and place to one side

17

Remove coolant vent line (6)

AR20.20-P-7441-01RQ

18

Remove low-temperature circuit coolant-expansion reservoir at reinforcement

AR09.41-P-0001LWB

19

Remove coolant hose at cooler for left low-temperature circuit and collect escaping coolant with a suitable container

AR20.20-P-7441-01RQ

20

Release and disconnect electrical connector at fan unit

21

Remove cold air intake (7)

22

Remove retaining clip (8) on cooler

23

Remove coolant hose (9) at engine and collect escaping coolant with a suitable container

AR20.20-P-7441-01RQ

24

Remove coolant hose (10) at cooler and collect escaping coolant with a suitable container

AR20.20-P-7441-01RQ

25

Remove coolant expansion reservoir at longitudinal member, place to one side and secure against falling down

AR20.30-P-4950LW

26

Remove coolant hose (11) at firewall and collect escaping coolant with a suitable container

AR20.20-P-7441-01RQ

27

Remove vacuum line (12)

28

Release and disconnect electrical connection (13) on outside temperature sensor

29

Remove lower air duct segment (14)

30

Release and disconnect electrical connection (15) at refrigerant pressure sensor

31

Remove struts (16, 17)

 Bolt, strut to cross member

*BA62.30-P-1003-01H

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

32

Remove brackets (18, 19) of lower engine compartment lining at fenders

33

Release and disconnect electrical connection on low-temperature circuit temperature sensor (20)

34

Release and disconnect electrical connection on low-temperature circuit circulation pump (21)

35

Release and disconnect electrical connections from electric power steering actuator motor

36

Unclip wiring harness of electric power steering at front axle carrier

37

Remove SCR catalytic converter clamp at front exhaust system

Engine 651 in model 205 with transmission 722.96
with code U77 (Diesel Emission control BLUETEC (SCR))

AR14.40-P-2006LWB

 Place AdBlue® metering valve at SCR catalytic converter with connected lines to one side.

 Installation: Observe installation position of clamp.

 Installation: Align components of exhaust system so that they are free of tension before tightening screw connections.

38

Secure SCR catalytic converter from falling down

39

Remove SCR catalytic converter from elastomer bearing

 Installation: Replace nut at elastomer bearing.

 Nut, elastomer bearing to front exhaust system bracket

*BA49.10-P-1007-02A

40

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

 Bolt, automatic transmission to engine

*BA27.40-P-1008-01A

41

Open fuel filler cap and reduce overpressure in fuel tank

42

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

 Installation: Observe markings.

43

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

 Record plug

*129589009100

44

Remove electric line of temperature sensor upstream of SCR catalytic converter at heat shield (26)

45

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

AR41.10-P-0050LW

46

Detach rear section of fender liners in front fenders in area of diagonal struts (27, 28, 30)

AR88.10-P-1300LW

47

Loosen trims (31) in area of the diagonal struts (27, 28, 30)

48

Unscrew screws of diagonal struts (27, 28) at torsion bar mount shells

Engine 651 in model 205 (except 205.4) with transmission 722.96

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

*BA61.10-P-1006-01L

49

Detach screws of diagonal struts (27, 28) at longitudinal members

Engine 651 in model 205 (except 205.4) with transmission 722.96

 Bolt, front diagonal strut to longitudinal member

*BA61.10-P-1007-01L

50

Remove diagonal struts (30)

Engine 651 in model 205.4 with transmission 722.96

 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

51

Disconnect steering coupling (29) from steering shaft

AR46.10-P-8000LW


Do not turn steering wheel when steering coupling (29) is removed.
Otherwise the clock spring contact will be destroyed.

52

Release and disconnect engine mount electrical connections in front wheel well

53

Remove rpm sensors at steering knuckles

AR42.30-P-0712LW

54

Unclip electric lines at spring links and steering knuckles

55.1

Remove brake caliper with brake linings and with attached brake hose free of tension to the vehicle

Engine 651 in model 205 with transmission 722.964-piston fixed-caliper brake

AR42.10-P-0070LWA

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

55.2

Detach brake calipers with brake caliper supports and fasten to vehicle free of tension with brake hose connected

Engine 651 in model 205 with transmission 722.961-piston floating caliper brake

AR42.10-P-0070LW

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

56

Remove steering knuckle from upper transverse control arms

AR33.25-P-0400LW


Secure steering knuckle.
This damages the joints.

57

Remove torsion bar linkage at steering knuckles

 Engine 651 in model 205 with transmission 722.96
with code M005 (4MATIC)Nut, torsion bar linkage to steering knuckle

*BA32.20-P-1006-02R

58

Remove suspension struts from spring control arms

Engine 651 in model 205 with transmission 722.96
with code 489 (AIRMATIC)

AR32.25-P-1017LWL

Engine 651 in model 205 with transmission 722.96
except code 489 (AIRMATIC)

AR32.25-P-1017LW

59

Support front axle carrier and secure entire engine-transmission unit and radiator package with suitable means against slipping and falling down



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

60

Remove rear engine carrier at frame floor assembly

AR22.10-P-4360LWB

 The rear engine support remains on the transmission.

61

Remove screw/bolts on front axle carrier from longitudinal members

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01Q

62

Lower engine transmission unit with front axle carrier and radiator package



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


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.

63

Install in the reverse order

Concluding tasks

64

Check oil level of engine



AP18.00-P-1811MP

65

Correct transmission oil level

AR27.00-P-0270SYZ

66

Check engine cooling system for leaktightness

AR20.00-P-1010LW

67

Check low-temperature circuit for leaktightness

AR09.41-P-1010LW

68

Perform wheel alignment check

AR40.20-P-0200LW

 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

69

Perform engine test run; as part of this check engine and major assemblies for proper operation and leak tightness

70

Check installation position and unobstructed movement of all components of the exhaust system

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1008-01A

Bolt, automatic transmission to engine

M1040

Nm

38

M1045

Nm

38

M1090

Nm

38

M12

Nm

–

 Front axle torsion bar

Number

Designation

Model 205
with code M005 (4MATIC)

BA32.20-P-1006-02R

Nut, torsion bar linkage to steering knuckle

Nm

80

 Front axle carrier

Number

Designation

Model 205

BA33.10-P-1001-01Q

Bolt, front axle carrier to longitudinal member

Nm

180

 Exhaust system

Number

Designation

Engine 651 in model 205

BA49.10-P-1007-02A

Nut, elastomer bearing to front exhaust system bracket

Nm

20

 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-1003-01H

Bolt, strut to cross member

M8

Nm

20

 Cross member and front reinforcement

Number

Designation

Model 205

BA62.30-P-1004-01H

Bolt, strut to soundproofing

M8

Nm

20

 Air conditioning

Number

Designation

Model 205

BA83.30-P-1004-01Q

Nut, refrigerant line to connecting point

Nm

12