Remove/install engine with front axle carrier

AR01.10-P-2500RT

Remove/install engine with front axle carrier

7.11.11

19.10.11

Value changed: Nut, link rod to stabilizer bar

*BA32.20-P-1004-02L

Value changed: Nut, link rod to stabilizer bar

*BA32.20-P-1004-02L

 

Remove/install

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

 Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A



On vehicles with memory package (driver seat, steering column, mirrors) code 275 the easy entry/exit must be disabled otherwise damage can occur when reconnecting the battery, as the driver seat and steering wheel can move into another position, when for example the driver door is opened or closed. Disabling takes place via the buttons on the steering wheel in the "comfort" menu of the multifunction display

1

Move DIRECT SELECT gear selector switch to position "N"

2

Release parking brake

3

Disconnect battery ground cable

 Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery.

AR54.10-P-0003RT

 Installation: On vehicles with memory package (driver seat, steering column, mirrors), code 275, before connecting the battery the holding device at the steering wheel must be removed.



Notes on battery

AH54.10-P-0001-01A

 Vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until ignition is switched off.

Remove the Keyless Go transmitter card or transmitter key from vehicle and store beyond reach of the transmitter (at least 2 m).

4

Secure vehicle on the lifting platform

AR00.60-P-0100RT

5

Remove partition wall between wheel wells

AR62.30-P-2400RT

6

Remove engine trim panel

AR01.10-P-2405RT

Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

7

Detach fuel line (1) from fuel distributor

 Release fuel pressure with pressure hose via service valve

AR07.03-P-1460-01GZ



*BA07.52-P-1001-01A



*119589046300

8

Drain air conditioning system

 Vehicles with automatic air conditioning code 580 or comfort automatic air conditioning code 581.

AR83.30-P-1760RT

9

Suction off hydraulic fluid from the expansion reservoir of power steering (7)



*210589007100

10

Drain coolant at radiator

AR20.00-P-1142GZ



Notes on coolant

AH20.00-N-2080-01A

11

Detach coolant hose at thermostat housing connection fitting (2)

 Check condition of coolant hose and hose clamps, replace if required.

12

Remove coolant hoses on upper coolant pump connection fitting (3) and lower coolant pump connection fitting (4)

 Check condition of coolant hoses and hose clamps, replace if required.

13

Remove lines for power steering on radiator connections (8)

 Seal all connections immediately.



*129589009100

14

Detach transmission fluid lines at radiator connections (9)

 Seal all connections immediately.



*129589009100

15

Remove brake booster vacuum line (6) at intake manifold

 In doing so, push outer face to the rear and pull out vacuum line.

16

Detach coolant hose (10) of heat exchanger from connection to firewall

 Check condition of coolant hose (10) and hose clamp; replace if necessary.

17

Detach refrigerant lines (5) from refrigerant compressor (A9)

 Installation: Replace seals.

AR83.55-P-5300RT

18

Fix steering wheel in center position



*129589012100

19

Disconnect steering shaft (16) on universal joint (17)

 The bolt (18) must be completely unscrewed since it is fed into a groove.



*BA46.10-P-1001-01K

20

Disconnect electrical connector (19) and purge line (19a) on purge control valve (Y58/1)

 Remove purge control valve (Y58/1) from rubber bracket and place onto engine with line still connected.

21

Disconnect engine wiring harness

AR01.00-P-2410RT

22

Remove wheels on front axle



Remove/install wheels

AP40.10-P-4050RT

23

Remove exhaust system up to rear flange connection

AR49.10-P-7000RT

24

Detach rear propeller shaft from transfer case

 Mark the rear propeller shaft relative to the propeller shaft flange.

 Installation: Observe tightening procedure for rear propeller shaft to transfer case.

AR41.10-P-0050-17GZ



*164589020700



*BA41.10-P-1001-01G

25

Detach right front brake pad contact sensor connector and left front brake pad contact sensor on brake caliper (26)

 Three connectors.

26

Remove guide pin (20) and brake caliper (26)

 Fasten brake caliper with line connected to upper transverse control arm (25).

 Installation: Replace guide bolts (20).



*BA42.10-P-1002-10L

27

Remove bracket (21)

 Installation: Install new cable ties.

28

Unscrew left front rpm sensor (L6/1) and or right front rpm sensor (L6/2) on wheel carrier

 Fasten all lines using a cable tie to suspension strut on corresponding side.



*BA42.30-P-1001-01I

29

Unscrew nut (23) on link rod of stabilizer bar (22)



*BA32.20-P-1004-02L

30

Unscrew nut (24) at the transverse control arm (25) and pry off the link



*BA33.20-P-1001-01L



*601589043300



*140589006300

31

Remove shock-absorber strut from lower transverse control arm

 Installation: Final tightening if vehicle on measuring platform or in K0 position, in order to avoid placing the rubber mount under stress.



*BA32.25-P-1002-01H

32

Remove left and right underfloor paneling

AR61.30-P-1001RT

33

Remove front wheel well lining

 Remove both sides.

AR88.10-P-1300RT

34

Position portable lifting platform with universal major assembly support at front axle carrier (33) and transmission oil pan

 Support front axle and transmission. When doing so ensure that mounting plates are correctly aligned.

 Before removal the complete unit must be secured with the aid of a tensioning strap!

Vehicle lift for major assemblies/scissors-type pallet forklift

gotis://A_01_07.1

35

Remove bolts (27) on engine crossmember (28)



*BA22.10-P-1005-03F



Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

36

Remove bolts (29) on front axle carrier (33) at front

 Installation: Replace screw/bolt (29).



*BA33.10-P-1001-01L

37

Remove bolts (30) and bolts (31) on stiffening plate (32)

 Installation: Replace bolts (30) and bolts (31).



*BA33.10-P-1003-01L

38

Remove bolts (34) at front axle carrier (33) at the rear

 Installation: Replace screw/bolt (34).



*BA33.10-P-1002-01L

39

Lower engine using front axle carrier (33)

40

Install in the reverse order

41

Fill power steering pump and bleed

AR46.30-P-0010RT

42

Fill cooling system

AR20.00-P-1142GZ

43

Inspecting cooling system for leaks

 If cylinder head gaskets are new, first warm up engine to operating temperature otherwise complete filling of the engine with coolant is not assured.

AR20.00-P-1010GZ

44

Check engine oil level

AR18.00-P-3035-01GZ



*120589072100



*BF18.00-P-1001-03U



*BF18.00-P-1002-03U



*BF18.00-P-1003-03U



*BF18.00-P-1004-03U

45

Check transmission oil level and correct if necessary

AR27.00-P-0270W

46

Carry out engine test run and check engine for proper operation and leaks

47

Perform wheel alignment check

AR40.20-P-0200RT

Number

Designation

Model 251

BA22.10-P-1005-03F

Bolt, rear engine crossmember to body

Nm

55

Number

Designation

Model 251

BA33.10-P-1001-01L

Self-locking bolt, front axle carrier (front) to longitudinal member

M141.5

Stage 1

Nm

130

Stage 2

°

-180

Stage 3

Nm

100

Stage 4

°

45

BA33.10-P-1002-01L

Self-locking bolt, front axle carrier at rear to longitudinal member

M141.5

Stage 1

Nm

130

Stage 2

°

-180

Stage 3

Nm

100

Stage 4

°

90

BA33.10-P-1003-01L

Bolt, stiffening plate to longitudinal member

M10

Nm

61

Number

Designation

Model 251

BA46.10-P-1001-01K

Bolt, steering coupling to steering shaft

Nm

33

Number

Designation

Model 251

BA42.30-P-1001-01I

Self-locking bolt, front axle rpm sensor to steering knuckle

Nm

8

Number

Designation

Model
251
except
251.077/
177

BA42.10-P-1002-10L

Guide pin on caliper support

Nm

55

Number

Designation

Model
251

BA32.20-P-1004-02L

Nut, link rod to stabilizer bar

Stage 1

Nm

100

2nd stage loosen

°

180

Stage 3

Nm

120

Stage 4

°

45

Number

Designation

Model 251

BA41.10-P-1001-01G

Self-locking bolt, propellor shaft to transfer case (to rear axle)

Stage 1

Nm

40

Stage 2

°

90

Number

Designation

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

Number

Designation

Model 251

BA33.20-P-1001-01L

Self-locking nut, upper ball joint out of upper transverse control arm to steering knuckle

Stage 1

Nm

20

Stage 2

°

90

Number

Designation

Model 251

BA32.25-P-1002-01H

Self-locking nut, shock absorber to wishbone

Nm

265

Number

Designation

Engine 113.964/971

BF18.00-P-1001-03U

Oil level

Maximum

mm

127

Minimum

mm

101

BF18.00-P-1002-03U

Oil dipstick reading
88 mm to 124 mm (oil level too low)

88 mm

Replenish oil quantity in liters

2.9

90 mm

Replenish oil quantity in liters

2.8

92 mm

Replenish oil quantity in liters

2.6

94 mm

Replenish oil quantity in liters

2.5

96 mm

Replenish oil quantity in liters

2.4

98 mm

Replenish oil quantity in liters

2.3

100 mm

Replenish oil quantity in liters

2.2

102 mm

Replenish oil quantity in liters

2.1

104 mm

Replenish oil quantity in liters

1.9

106 mm

Replenish oil quantity in liters

1.8

108 mm

Replenish oil quantity in liters

1.7

110 mm

Replenish oil quantity in liters

1.5

112 mm

Replenish oil quantity in liters

1.4

114 mm

Replenish oil quantity in liters

1.2

116 mm

Replenish oil quantity in liters

1.0

118 mm

Replenish oil quantity in liters

0.9

120 mm

Replenish oil quantity in liters

0.7

122 mm

Replenish oil quantity in liters

0.5

124 mm

Replenish oil quantity in liters

0.3

BF18.00-P-1003-03U

Oil dipstick reading
126 mm to 128 mm (oil level correct)

126 mm

Oil quantity in liters

0.0

127 mm

Oil quantity in liters

0.0

128 mm

Oil quantity in liters

0.0

BF18.00-P-1004-03U

Oil dipstick reading
130 mm to 138 mm (oil level too high)

130 mm

Extract oil quantity in liters

-0.3

132 mm

Extract oil quantity in liters

-0.5

134 mm

Extract oil quantity in liters

-0.7

136 mm

Extract oil quantity in liters

-0.9

138 mm

Extract oil quantity in liters

-1.1