Remove/install engine with transmission

AR01.10-P-2401LFD

Remove/install engine with transmission

16.01.2018

Engine

642 in model 222

except code M005 (4MATIC)

1

Coolant hose

6

Vacuum line

2

Coolant hose

17

Heat shield

3

Coolant hose

18

Electrical connector

4

Coolant hose

19

Vehicle wiring harness

5

Coolant hose

7

Electrical connector

8

Electrical wiring harnesses

9

Electrical connector

10

Bulkhead connecting point

11

Screw

12

Electrical connector

13

Fuel hoses

16

Bolts

14

Ground cable

 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

 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

 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

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-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

Notes on coolant

AH20.00-N-2080-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

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

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

AH00.00-P-0020-01A

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

 

Remove/install

1

Deactivate easy entry/exit feature

2

Shift transmission into neutral position

3

Release parking brake

4

Disconnect ground cable at battery

AR54.10-P-0003LF

5

Suction off engine oil



AP18.00-P-0101EWO

6

Secure vehicle on vehicle lift

 Vehicle hoist securing tool

*171589013100

7

Remove engine compartment paneling

AR61.20-P-1105LF

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

8

Drain off coolant

AR20.00-P-1142LF

9

Remove left and right air filter housing

AR09.10-P-1150SXI

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

10

Remove fan unit

AR20.40-P-5050LF

11

Mount protective plate on radiator



WF58.50-P-0110-01A

12

Remove coolant hose (1) from cooler and seal openings with suitable stop plugs or protective covers

AR20.20-P-7441-01RQ

 Installation:
Thoroughly clean connections, check sealing rings and catch springs for damage and correct seating; replace if necessary.
Leaks can occur otherwise.

 Set of protective covers

*001589019100

 Record plug

*129589009100

13

Remove charge air cooler

AR09.41-P-6819LFD

14

Remove coolant hose (2) from coolant line, place to one side and seal openings with suitable stop plugs or protective covers

 Installation: Replace clamp if necessary.

 Set of protective covers

*001589019100

 Record plug

*129589009100

15

Remove coolant hose (3) at connection fitting of coolant pump and seal openings with suitable stop plugs or protective covers

AR20.20-P-7441-01RQ

 Installation:
Thoroughly clean connections, check sealing rings and catch springs for damage and correct seating; replace if necessary.
Leaks can occur otherwise.

 Set of protective covers

*001589019100

 Record plug

*129589009100

16

Remove coolant hose at oil cooler and seal openings with suitable stop plugs or protective covers

Engine 642 in model 222 with transmission 725.0
except code M005 (4MATIC)

AR27.55-P-1000LFD

Engine 642 in model 222 with transmission 722.9
except code M005 (4MATIC)

AR27.55-P-1000LF

 Set of protective covers

*001589019100

 Record plug

*129589009100

17

Remove coolant hose (4) from low-temperature circuit coolant expansion reservoir and seal openings with suitable stop plugs

 Record plug

*129589009100

18

Remove heat shield (17)

19

Remove coolant hose (5) of exhaust gas recirculation actuator at firewall and seal openings with suitable stop plugs or protective covers

AR20.20-P-7441-01RQ

 Installation:
Thoroughly clean connections, check sealing rings and catch springs for damage and correct seating; replace if necessary.
Leaks can occur otherwise.

 Set of protective covers

*001589019100

 Record plug

*129589009100

20

Remove vacuum line (6) on bulkhead (10) connecting point and place to one side

21

Remove right engine cover, release and disconnect electrical connectors (7, 9)

22

Remove electrical wiring harness (8) at engine compartment prefuse box and on bulkhead and lay on the engine

AR01.00-P-2410-02LFD

 Nut, positive terminal to engine compartment prefuse box

*BA54.15-P-1002-01J

23

Expose electrical lines of switchable engine mounts, release and disconnect electrical connections

AR22.10-P-1260LFD

24

Release and disconnect electrical connector (18)

25

Remove vehicle wiring harness (19) and place on left engine cover

AR01.00-P-2410-02LFD

26

Remove screw (11)

 Screw/bolt, refrigerant line to oil filter housing

*BA83.55-P-1009-01A

27

Remove poly-V belt

AR13.20-P-0001LFD

28

Release and disconnect electrical connection (12) from refrigerant compressor

29

Release bracket for transmission oil lines at oil pan

Engine 642 in model 222 with transmission 725.0
except code M005 (4MATIC)

AR27.55-P-0600LFD

Engine 642 in model 222 with transmission 722.9
except code M005 (4MATIC)

AR27.55-P-0600LF

 Release bracket for oil lines until lower screw of refrigerant compressor is accessible.

30

Remove screws/bolts of refrigerant compressor, and place refrigerant compressor to one side with lines connected

AR83.55-P-5300LF

31

Remove fuel hoses (13) at fuel pipes and seal openings with suitable stop plugs

 Installation:
Replace collar clamps.
Leaks can occur otherwise.

 Record plug

*129589009100

32

Remove ground line (14) from transmission

 Engine 642 in model 222 with transmission 722.9
except code M005 (4MATIC)Bolt, ground line to transmission housing

*BA27.40-P-1013-01A

 Engine 642 in model 222 with transmission 725.0
except code M005 (4MATIC)Bolt, ground line to transmission housing

*BA27.10-P-1024-04H

33

Remove the diesel particulate filter

AR49.10-P-5501LFD

34

Remove oxygen sensor

AR07.04-P-0080LFD

35

Support transmission using major assembly mount and support plate



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B



000 588 10 62 00 Support plate

WS26.00-P-3309B

36

Remove screws/bolts (16), and remove rear engine crossmember

AR22.10-P-1180LF


Never use an impact wrench/driver or compressed air tools for removing or screwing in screws/bolts (16).
Otherwise, threads are damaged.

 Rear engine mount remains on transmission.

37

Remove propeller shaft at transmission, and secure on vehicle to prevent falling down

AR41.10-P-0040-01LF



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

 Installation: Install new self-locking nuts.

 The flexible coupling remains on the propeller shaft.

 Flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01J

 Counterholder

*176589004000

38

Check flexible coupling for wear and damage

If wear or damage present



Replacing flexible coupling.

AR41.10-P-0040-01LF



Drift for releasing the fitting sleeves in the flexible couplings

WF58.50-P-4110-01A

 Flexible coupling to transmission or front propeller shaft

*BA41.10-P-1001-01J

 Counterholder

*176589004000

39

Install rear engine crossmember

AR22.10-P-1180LF

40

Remove support plate and assembly mount



000 588 10 62 00 Support plate

WS26.00-P-3309B



000 588 11 62 00 Major assembly mount

WS01.00-P-0092B

41

Remove lower screws/bolts at left and right front engine mount from below

AR22.10-P-1260LFD

42

Hook boom crane with load tilter in all available engine lifting eyes



000 588 00 62 00 Load tilter

WS01.00-P-0102B

 Commercially available devices/tools
Boom crane

43

Remove upper screw/bolt on front left and right engine mount from above

AR22.10-P-1260LFD

44

Lower engine with transmission backwards, and lift out


Ensure that engine does not collide with other components during removal or installation.
Otherwise damage will occur.

 Two helpers required.

45

Install in the reverse order

46

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

 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

47

Perform an engine test run, check engine and transmission for proper operation and leaktightness while doing so

48

Install lower engine compartment paneling

AR61.20-P-1105LF

49

Install upper engine cover

 Automatic transmission complete

Number

Designation

Transmission 725.0

BA27.10-P-1024-04H

Bolt, ground line to transmission housing

Nm

20

 Housing

Number

Designation

Transmission 722.9

BA27.40-P-1013-01A

Bolt, ground line to transmission housing

Nm

9

 Propeller shaft

Number

Designation

Model 222

BA41.10-P-1001-01J

Flexible coupling to transmission or front propeller shaft

Self-locking nut

Nm

68

Direct threaded connection

Stage 1

Nm

60

Stage 2

°

90

 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

 Refrigerant compressor

Number

Designation

Engine 642 in model 222

BA83.55-P-1009-01A

Screw/bolt, refrigerant line to oil filter housing

Nm

14