Remove/install engine with front axle carrier

AR01.10-P-2500RFA

Remove/install engine with front axle carrier

13.03.2018

Engine

276.8 in model 251

Modification notes

24.09.2014

Überwurfmutter Kraftstoffleitung an Kraftstoffverteiler

BA07.03-P-1001-01D

2

Air cleaner housing

5

Steering coupling

8

Fuel line

3

Refrigerant line

6

Low-temperature circuit coolant expansion reservoir

9

Coolant hose

4

Coolant hose

7

Vacuum line

11

Coolant hose

15

Refrigerant line

19

Connecting point for low-temperature circuit coolant expansion reservoir

12

Coolant hose

16

Purge valve

20

Charge air cooler

13

Coolant hose

18

Radiator

23

Oil line

30

Transverse control arm

39

Transfer case

25

Oil line

33

Stiffening plate

40

Heat shield

26

Front axle carrier

34

Exhaust pipes with catalytic converters

42

Propeller shaft

27

Bolts

35

Rear engine crossmember

43

Stiffening plate

28

Brake caliper

37

Stiffening plate

44

Switchover valve

29

Steering knuckle

38

Center muffler

45

Coolant hose

46

Coolant pump

47

Coolant hose

 Warning

Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.

Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 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

 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

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

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 threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on AIRmatic

Engine 276.8 in model 251
with code 489 (AIRMATIC)

AH32.22-P-1000-02RT

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

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

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

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

2

Secure vehicle on vehicle lift

AR00.60-P-0100RT

3

Reduce pressure in air suspension with vehicle diagnosis system

Engine 276.8 in model 251
with code 489 (AIRMATIC)



AD00.00-P-2000-04A

4

Deactivate easy entry/exit feature

Engine 276.8 in model 251
with code P64 (Memory package)

5

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

 Retainer device

*129589012100

6

Disconnect ground line from battery

AR54.10-P-0003RT

7

Remove lower engine compartment paneling

AR61.20-P-1105RT

 Installation: Only install lower engine compartment linings once leak test has been completed.

8

Drain coolant at radiator (18)

AR20.00-P-1142GZC

9

Drain coolant from low-temperature circuit

10

Remove partition wall between wheel wells

AR62.30-P-2400RT

11

Remove water drain above windshield wiper system

AR83.25-P-1406RT

12

Unclip coolant hose (13) on charge air cooler (20) and place to one side

13

Remove left and right air filter housing (2)

AR09.10-P-1150GQC

14

Drain air conditioning system

AR83.30-P-1760RT

15

Disconnect refrigerant line (3) at upper separating point in engine compartment 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

16

Disconnect vacuum line (7) from vacuum pump and place to one side

17

Relieve fuel pressure over diagnostic socket

AR07.03-P-1460-01VA

 Cap on service connection

*BA07.03-P-1007-01D

 Pressure hose

*119589046300

18

Remove fuel line (8) at fuel distributor and seal openings with suitable stop plugs

 Union nut, fuel line to fuel distributor

*BA07.03-P-1001-01D

 Record plug

*129589009100

19

Remove coolant hose (9) to heater cooler at bulkhead and place to one side

20

Remove steering coupling (5) at upper steering shaft

AR46.10-P-8000RT


Do not turn steering wheel when steering coupling (5) is removed.
Otherwise the clock spring contact will be destroyed.

21

Unclip purge valve (16) at coolant expansion reservoir and place to one side

22

Disconnect upper coolant hose (4) on cooler (18)

AR09.41-P-1311-01AL

23

Remove charge air cooler (20) with connected lines and coolant hoses and place to one side

AR09.41-P-6819GQC

24

Suction off oil from expansion reservoir of power steering

 Hand pump

*210589007100

25

Disconnect hydraulic lines at radiator (18) and seal openings with suitable stop plugs


Thoroughly clean area around separating point before opening hydraulic system.
Even the smallest of dirt particles can result in damage or even a total failure of the hydraulic system.

 Record plug

*129589009100

26

Disconnect engine wiring harness to remove engine

AR01.00-P-2410-02RTC

27

Remove coolant hose (11) at connecting point to charge air cooler circulation pump

AR09.41-P-6925RTC

28

Remove coolant hose (12) at connecting point of low-temperature circuit coolant expansion reservoir (19) from low-temperature circuit coolant expansion reservoir (6)

AR09.41-P-0001GQC

29

Disconnect coolant hose (47) on connection piece to coolant pump (46)

30

Remove heat shield (40) at transfer case (39)

31

Remove refrigerant line (15) at condenser, place to one side 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/bolt, high-pressure line to fluid reservoir

*BA83.30-P-1001-01J

 Record plug

*129589009100

32

Disconnect lower coolant hose at radiator (18)

33

Disconnect coolant hose (45) at switchover valve (44) of stationary heater and unclip at longitudinal member

Engine 276.8 in model 251
with code 228 (Auxiliary heater)

34

Remove oil lines (23, 25) at oil cooler and at radiator (18), unclip from blower housing and seal openings with suitable stop plugs and place to one side

AR27.10-P-0501-03RT

 Installation: Replace seals and safety clips.

 Record plug

*129589009100

35

Remove upper transverse control arm at steering knuckles (29)

AR33.25-P-0400RT

36

Remove brake calipers (28) with connected lines at brake caliper supports, place to one side and secure against falling down

AR42.10-P-0070RT

37

Remove rpm sensors at steering knuckles (29), unclip from brackets and place to one side

AR42.30-P-0712RT

38

Remove suspension struts at lower transverse control arms (30)

AR32.25-P-1017RT

39

Remove stabilizer bar torsion bar linkage at suspension struts

 Nut, torsion bar linkage to front suspension strut

*BA32.20-P-1003-02L

40

Remove exhaust pipes with catalytic converters (34) at separating point from center muffler (38)

AR49.10-P-5500GQC

41

Remove propeller shaft (42) at transmission output flange of transfer case (39) and secure against falling down using suitable means

AR41.10-P-0050RT

42

Support front axle carrier (26) with lifting platform and mounting plates and secure entire engine-transmission unit with suitable means 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.

43

Remove rear engine crossmember (35) together with stiffening plates (37, 43)

AR22.10-P-1180GZD

44

Remove screws of stiffening plates (33) at longitudinal members

 Bolt, stiffening plate to longitudinal member

*BA33.10-P-1003-01L

45

Remove screws (27) from longitudinal members

AR33.10-P-0100RT

 Installation: Replace screws/bolts (27).

46

Lower engine transmission unit with front axle carrier (26)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Make sure that engine/transmission unit does not contact body panels or major assemblies.
Do not kink, crush or subject lines to tension.
This leads to component and/or line damage.

47

Install in the reverse order

Concluding tasks

48

Check transmission oil level and correct if necessary

AR27.00-P-0270W

49

Check engine oil level and correct if necessary



AP18.00-P-1811MP

50

Fill steering and bleed

AR46.30-P-0010RT

51

Perform wheel alignment check

AR40.20-P-0200RT

 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

52

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

 Injection nozzles, injection valves, lines

Number

Designation

Engine 276

BA07.03-P-1001-01D

Union nut, fuel line to fuel distributor

Stage 1

Nm

15

Stage 2

°

90

 Injection nozzles, injection valves, lines

Number

Designation

Engine 276

BA07.03-P-1007-01D

Cap on service connection

Plastic

Nm

2

Metal

Nm

15

 Front axle torsion bar

Number

Designation

Model 251

BA32.20-P-1003-02L

Nut, torsion bar linkage to front suspension strut

Stage 1

Nm

100

Stage 2: Loosen

°

180

Stage 3

Nm

120

Stage 4

°

45

 Front axle carrier

Number

Designation

Model 251

BA33.10-P-1003-01L

Bolt, stiffening plate to longitudinal member

M10

Nm

61

 Air conditioning

Number

Designation

Model 251

BA83.30-P-1001-01J

Nut/bolt, high-pressure line to fluid reservoir

Nm

11