Remove/install engine with front axle carrier

AR01.10-P-2500OMD

Remove/install engine with front axle carrier

14.2.12

21.10.11

Value changed: screw/bolt, rear engine support to frame floor assembly

*BA22.10-P-1005-03E

 

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 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.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

 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 to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

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

AS00.00-Z-0013-01A



Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SF

1

Move selector lever into position "N"

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

2

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

 Do not connect quiescent current retention unit.

AR54.10-P-0003CW



Notes on battery

AH54.10-P-0001-01A

3

Drain air conditioning system

Except model 204.9

AR83.30-P-1760CW

4

Disconnect refrigerant lines to connecting point

Except model 204.9

5

Secure vehicle on vehicle lift

AR00.60-P-0100CW

 Lifting platform retainer

*171589013100

6

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

 The steering wheel must not be turned when the steering coupling is detached, otherwise the clock spring contact will be destroyed.

 Holding device

*129589012100

7

Remove lower engine compartment paneling

Model 204.9

AR61.20-P-1105CY

Model 204

8

Drain coolant

 Installation: Pressure check cooling system only after engine has reached operating temperature otherwise, leakage can occur at cylinder head gasket.

AR20.00-P-1142CW



Notes on coolant

AH20.00-N-2080-01A

 Mixture ratio for coolant

*BF20.00-P-1001-04A

 Tester cap

*210589009100

 Cooler vacuum filling device

*285589002100

9

Remove cylinder head cover trim

10

Remove engine intake air duct upstream of air filter housing

11

Remove air filter housing

AR09.10-P-1150CD

12

Disconnect electrical connector (3) at pressure differential sensor (DPF) (B28/8)

13

Disconnect electrical connectors (1 and 2), unhook generator starter wiring harness (8) and lay down to side

14

Disconnect alternator-starter-wiring harness (8) on front prefuse box (F32)

 To do this remove cover (7), loosen nut (9) and unclip starter alternator wiring harness (8) up to engine.

15

Remove poly-V belt

Model 204.9

AR13.20-P-0001OMD

16

Remove poly-V belt guide pulley (36)

Model 204.9

 Start by removing screw/bolts (37).

AR13.20-P-0001OMD

 Screw/bolt, guide pulley to major assembly carrier

*BA13.25-P-1002-01W

17

Detach coolant hoses (10, 11, 12 and 13) on engine

Henn coupling

AR09.41-P-1311-01AL

 In order to avoid leaks, check condition of coolant hoses (10, 11, 12 and 13), hose clamps and hose couplings; replace if necessary.

18

Remove screw/bolt (14) and place coolant hose (13) to one side

19

Detach coolant hose (15) on bulkhead

Henn coupling

AR09.41-P-1311-01AL

 To do this disconnect hose coupling (16).

20

Release and detach vacuum line (17)

21

Extract oil from expansion reservoir of power steering pump

Model 204.9

 Hand pump

*210589007100

22

Remove return hose (4) from expansion reservoir of power steering pump

Model 204.9

 Collect escaping oil with rags and seal connections immediately.

 Set of stop plugs

*129589009100

23

Detach high-pressure expansion hose on quick coupling (5) from power steering pump .

Model 204.9

 Collect escaping oil with rags and seal connections immediately.

 Installation: replace O-rings.

 Set of stop plugs

*129589009100

24

Disconnect pressure line D1 to power steering pump

Model 204.9

25

Detach electrical connector from refrigerant compressor (A9)

Model 204.9

26

Remove screw/bolts for A/C compressor and set aside A/C compressor

Model 204.9

 Attach A/C compressor at side in bottom of engine compartment with lines connected.

 Screw/bolt, refrigerant compressor to major assembly carrier

*BA83.55-P-1001-01W

 Screw/bolt, refrigerant compressor to engine support

*BA83.55-P-1002-01W

27

Disconnect charge air hose upstream and downstream of charge air cooler on the engine

 To do this, release the safety clamps.

AR09.41-P-8619CD

 Small quantities of oil and oil marks in the charge air hoses are normal, and are due to crankcase ventilation.

 Installation: Check sealing rings for damage and replace if required in order to avoid leakage. Ensure safety clamps are exactly installed.

28

Separate lines at separation point of automatic transmission oil cooler

29

Loosen screw/bolt on clamp (18) and remove exhaust intermediate pipe from diesel particulate filter (19)

 Tie up connecting pipe of exhaust system and secure flexible coupling element with assembly tool in order to avoid damage to flexible coupling element.

 Screw/bolt, connecting pipe clamp to diesel particulate filter

*BA49.10-P-1022-01AC

 Assembly tool

*651589066300

30

Remove shield (20) and disconnect electrical connector (21)

31

Detach ground line (22) on transmission

Screw/bolt, ground strap to transmission

*BA15.10-P-1002-05C

32

Disconnect fuel lines (23)

 Open tank cap in order to reduce the overpressure in the tank. Mark fuel lines in order to exclude any later mix up. Seal connections.

 Installation: Replace hose clamps.

Clamp

*000589403700

 Set of stop plugs

*129589009100

33

Remove shift rod (25) from range selector lever of transmission

 For this purpose loosen securing clamp (24) and remove shift rod (25) from selector lever

 Installation: Replace securing clamp (24).

34

Detach underbody panel (26).

35

Remove heat shield (27) in area of propeller shaft center support bearing

 Start by removing screw/bolts (28).

36

Unscrew bolts (29) and remove vibration damper (30)

Screw/bolt, vibration damper to transfer case

*BA28.10-P-1007-01E

37

Mark propeller shaft

 Apply color markings to the transmission to indicate position of the propeller shaft relative to the output flange. This ensures that the components are reinstalled at the factory installation position.

38

Remove propeller shaft at transmission

 To do this detach fitting sleeves from flexible couplings. The flexible coupling remains on the propeller shaft.

AR41.10-P-0050-09TX



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

 Check flexible coupling for wear and damage; replace if necessary.

 Installation: Install new self-locking nuts.

 Self-locking nut, flex disk to transmission or front propeller shaft

*BA41.10-P-1001-01I



Drift for loosening fitting sleeves in flex disks.

WF58.50-P-4110-01A

39

Remove front axle shafts

AR33.30-P-0620CWX

40

Remove rear section of front wheel well panel

41

Detach front door sill panels

42

Remove diagonal struts (33)

 Installation: The screw/bolts of the diagonal struts (33) may only be securely tightened when the vehicle is standing with its wheels on the ground.

 Screw/bolt, diagonal strut mount on front axle carrier/longitudinal member

*BA61.10-P-1004-01H

 Set of engine mount wrenches

*001589011600

43

Disconnect steering coupling

AR46.10-P-8000CW

44

Disconnect engine mount electrical connectors in wheel well

45

Support front axle carrier with lifting platform and aggregate mount and secure whole engine transmission unit against slipping and falling down with a tensioning strap

 Ensure even alignment of support plates.

Lifting platform for major assemblies/scissor-type pallet forklift

gotis://A_01_07.1

46

Remove rear engine crossmember (32)

 Start by removing screw/bolts (31). The rear engine crossmember (32) remains attached to transmission.

 Screw/bolt, rear engine support to frame floor assembly

*BA22.10-P-1005-03E

47

Remove support struts (34) from vehicle underfloor and front axle carrier

Model 204.9

 Fixing of support (strut)

*BA33.10-P-1002-01M

48

Unscrew screw/bolt (35) on front axle carrier from longitudinal members

 Installation:Replace screw/bolts (35).

 Screw/bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01M

49

Lower engine transmission unit with front axle carrier

 Ensure that engine does not hit up against components when removing and installing in order to avoid damage to the engine or other components.

 Installation: Pay attention to correct seating of the rubber supports for the radiator support.

50

Remove engine

51

Install in the reverse order

52

Fill power steering pump and bleed

Model 204.9

AR46.30-P-0010CW

 Power steering

*BF46.20-P-1001-01E

53

Perform wheel alignment check

AR40.20-P-0200CW

54

Read out fault memory and erase

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A



Checking

55

Check engine oil level

 Engine oil level must be between "Min" and "Max", otherwise engine damage could occur.

AR18.00-P-3035-01T

 Oil level

*BF18.00-P-1001-03AD

 Dipstick indication 97 mm to 112 mm (oil level too low)

*BF18.00-P-1002-03AD

 Oil dipstick indication 114 mm to
118 mm (oil level correct)

*BF18.00-P-1003-03AD

 Oil dipstick indication 120 mm to
124 mm (oil level too high)

*BF18.00-P-1004-03AD

 Dipstick

*120589072100

56

Check transmission oil level and correct if necessary

AR27.00-P-0270SYZ

57

Inspect cooling system for leaks

 Engine with new cylinder head gasket:

Pressure check the cooling system only after the engine has reached the operating temperature; otherwise leakage could occur.

AR20.00-P-1010CW

58

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

59

Check for leaks with engine running

Number

Designation

Engine 651

BA01.45-P-1003-01S

Oil drain screw on oil pan

Nm

30

Number

Designation

Engine
651 except 651.901/930

Engine 651.901/930

BA13.25-P-1002-01W

Screw/bolt, guide pulley to major assembly carrier

M8

Nm

25

45

M10

Nm

45

-

Number

Designation

Model
204

BA15.10-P-1002-05C

Screw/bolt, ground strap to transmission

M8

Nm

27

M10

Nm

-

Number

Designation

Model
204
except 4MATIC, model 204.9

Model
204.9
with
4MATIC

BA22.10-P-1005-03E

Screw/bolt, rear engine support to frame floor assembly

Nm

70

60

Number

Designation

Trans-mission
722.96

BA28.10-P-1007-01E

Screw/bolt, vibration damper to transfer case

Nm

40

Number

Designation

Model
204

BA33.10-P-1001-01M

Screw/bolt, front axle carrier to longitudinal member

Nm

180

BA33.10-P-1002-01M

Fixing of support (strut)

Nm

110

Number

Designation

Model
204

BA41.10-P-1001-01I

Self-locking nut, flex disk to transmission or front propeller shaft

M12

Nm

68

Number

Designation

Engine
642, 646, 651
in model
204

BA49.10-P-1022-01AC

Clamp nut/bolt between catalytic converter/connecting pipe/diesel particulate filter

Nm

35

Number

Designation

Model 204

BA61.10-P-1004-01H

Screw/bolt, diagonal strut mount on front axle carrier/longitudinal member

Nm

50

Number

Designation

Engine 651
in model 204, 207 with
Denso refrigerant compressor

Engine 651
in model 204, 207 with
Valeo refrigerant compressor

BA83.55-P-1001-01W

Screw/bolt, refrigerant compressor to major assembly carrier

Nm

20

20

BA83.55-P-1002-01W

Screw/bolt, refrigerant compressor to engine support

Nm

20

20

Number

Designation

Engine
651 without particulate filter except in model
246

Engine
651 with particulate filter
except in model
246

BF18.00-P-1001-01Z

Engine oil

Filling capacity
(oil and filter change)

Liters

6.5

6.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-03A

-

Sheet

BB00.40-P-0228-05A

-

Sheet

BB00.40-P-0228-51A

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

-

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

BB00.40-P-0229-51A

Number

Designation

Engine
651.912
in model 204

BF18.00-P-1001-03AD

Oil level

Maximum

mm

160

Minimum

mm

128

BF18.00-P-1002-03AD

Dipstick indication
128 mm to 155 mm (oil level too low)

128 mm

Replenish oil quantity in liters

2

129 mm

Replenish oil quantity in liters

1.5

131 mm

Replenish oil quantity in liters

1.5

133 mm

Replenish oil quantity in liters

1.5

135 mm

Replenish oil quantity in liters

1.5

137 mm

Replenish oil quantity in liters

1.5

139 mm

Replenish oil quantity in liters

1

141 mm

Replenish oil quantity in liters

1

143 mm

Replenish oil quantity in liters

1

145 mm

Replenish oil quantity in liters

1

147 mm

Replenish oil quantity in liters

1

149 mm

Replenish oil quantity in liters

0.5

151 mm

Replenish oil quantity in liters

0.5

153 mm

Replenish oil quantity in liters

0.5

155 mm

Replenish oil quantity in liters

0.5

BF18.00-P-1003-03AD

Oil dipstick indication 157 mm to 161 mm (oil level correct)

157 mm

Oil quantity in liters

0.0

159 mm

Oil quantity in liters

0.0

161 mm

Oil quantity in liters

0.0

BF18.00-P-1004-03AD

Oil dipstick indication 164 mm to 173 mm (oil level too high)

164 mm

Extract oil quantity in liters

-0.5

166 mm

Extract oil quantity in liters

-0.5

168 mm

Extract oil quantity in liters

-0.5

170 mm

Extract oil quantity in liters

-0.5

173 mm

Extract oil quantity in liters

-1

Number

Designation

ENGINE all

BF20.00-P-1001-04A

Mixture ratio for coolant

Antifreeze/water

up to -37°C

50/50

up to -45°C

55/45

Specifications for service products

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

Number

Designation

Model
204

BF46.20-P-1001-01E

Power steering

Filling capacity

Liters

0.8

MB steering gear oil

Sheet

BB00.40-P-0345-00A