Remove/install engine with transmission · ar0110p2401sr · Mercedes-Benz WIS

AR01.10-P-2401SR

Remove/install engine with transmission

14.03.2018

Engine

281 in model 453

Modification notes

12.07.2017

Operation steps revised.

Operation step 1 to operation step 77.

P01.10-3243-09

Shown on ENGINE 281.920

1	Engine wiring harness	6	Vacuum lines	10	Nuts
2	Fuel line	7	Intake manifold	19	Cable tie
3	Fuel distributor	8	Electrical line
4	Air intake hose	9	Air cleaner housing

P01.10-3245-08

Shown on engine 281.910 with transmission 700.41

5	Coolant hoses	22	Ground cable	25	Coolant hoses
20	Electrical connector	23	Nut
21	Nut	24	Ground cable

P01.10-3244-09

Shown on engine 281.920 with transmission 700.12

11	Ground cable	14	Refrigerant line	17	Rear muffler
12	Front engine mount	15	Refrigerant line	18	Rear axle shafts
13	Bracket	16	Electrical connector	A9	Refrigerant compressor

 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
 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. 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
 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
 Caution	Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil	Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles.	AS00.40-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
Topical note	Notes on coolant		AH20.00-N-2080-01A
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 avoiding damage through contamination and foreign objects		AH00.00-P-5000-01A
	Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases		AH01.10-P-0001-01A
	Notes on repair work on suspension components		AH00.00-P-0100-01A
	Remove
1	Secure vehicle against rolling
2	Shift transmission into neutral position	Engine 281 in model 453 with transmission 700.41
3	Disconnect ground line from battery		AR54.10-P-0003SR
4	Raise vehicle using the vehicle lift and secure in place		AR00.60-P-0100SR
5	Lower fuel tank until charging current line can be accessed		AR47.10-P-4100SR
6	Remove the charge current line and fix on the engine		AR15.18-P-0001-01SR
7	Release and disconnect electrical connector (20)
8	Unscrew nut (21) and remove ground line (22)
9	Unscrew nut (23) and remove ground line (24)	Engine 281 in model 453 with transmission 700.41
10	Remove fan unit		AR20.40-P-5614SR
11	Release and disconnect all electrical connectors at ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008SR
12	Disconnect cable tie (19) from engine wiring harness (1)
13	Unclip engine wiring harness (1) at body and lead into the engine compartment
14	Drain off coolant		AR20.00-P-1142SR
15	Remove rear muffler (17)		AR49.10-P-4823SR
16	Remove rear axle crossmember		AR35.15-P-0250SR
17	Remove control arms		AR35.15-P-0204SR
18	Remove rear axle shafts (18)	Engine 281 in model 453
		Engine 281 in model 453 with transmission 700.12	AR35.30-P-0620SR
		Engine 281 in model 453 with transmission 700.41	AR35.30-P-0620SRA
19	Remove poly-V belt		AR13.22-P-1202SR
20	Remove fuel line (2) from fuel distributor (3) and seal exposed connections with suitable stop plugs	 Record plug	*129589009100
21	Remove air intake hose (4) and seal exposed connections with suitable protective covers	 Set of protective covers	*001589039100
22	Remove coolant hoses (5)	 Hose clamp pliers	*003589033700
23	Remove coolant hoses (25)	Engine 281.910 in model 453
		 Hose clamp pliers	*003589033700
24.1	Remove vacuum lines (6) from intake manifold (7)	Engine 281.920 in model 453
24.2	Remove vacuum lines (6) from charge air pipe	Engine 281.910 in model 453
25	Release and disconnect electric line (8) at bleed valve of fuel tank and expose at air filter housing (9)
26	Remove hydraulic line from clutch slave cylinder	Engine 281 in model 453 with transmission 700.12	AR25.20-P-1000SR
27	Remove ground line (11) from transmission housing
28.1	Remove shift cables from transmission	Engine 281 in model 453 with transmission 700.12
			AR26.60-P-6626SR
28.2	Remove cable for selector lever lock from transmission	Engine 281 in model 453 with transmission 700.41
			AR27.60-P-0002SR
29	Remove front engine mount (12) at transmission housing, detach at body side and swivel downward		AR22.10-P-4330SR
30	Remove bracket (13) of refrigerant line (14) from crankcase	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
31	Unfasten nuts (10) for rear engine mount	 Do not totally unscrew nuts (10) for rear engine mount yet.
32	Position main assembly lifting table and universal main assembly mount		AR01.10-P-2400-06SR
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Do not load oil pan in the center and not in the area of the drain screw. The oil pan can be damaged otherwise.
		 Adaptation	*453589016200
33	Unscrew nuts (10) for rear engine mount
34	Lift vehicle using a vehicle lift until the A/C compressor (A9) is accessible	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
		 Ensure that no electrical lines and hose get pinched.
		If the threaded pins are tilted in rear engine mounts
		
		Unfasten the threaded pins with light blows out of the rear engine mounts.
35	Remove refrigerant compressor (A9) from crankcase and release and disconnect electrical connector (16)	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
			AR83.55-P-5310SR
		 Do not remove refrigerant lines (14, 15) from A/C compressor (A9).
36	Fix A/C compressor (A9) at a suitable location with cable ties to the body	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
37	Lift vehicle on vehicle lift	 Ensure that no electrical lines and hose get pinched.
38	Pull engine with transmission out from under vehicle
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Adaptation	*453589016200
	Install
39	Attach engine with transmission to major assembly lifting platform and universal major assembly mount	If engine with transmission was removed from major assembly lifting platform and universal major assembly mount.
			AR01.10-P-2400-06SR
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Do not load oil pan in the center and not in the area of the drain screw. The oil pan can be damaged otherwise.
		 Adaptation	*453589016200
40	Position engine with transmission under vehicle
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Adaptation	*453589016200
41	Lower vehicle using a vehicle lift until the A/C compressor (A9) can be attached	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
42	Install A/C compressor (A9) and contact electrical connection (16)	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
			AR83.55-P-5310SR
43	Lower vehicle using a vehicle lift until the nuts (10) can be screwed onto the threaded pin of the rear engine mount	 Ensure that the threaded pin cannot tilt in the rear engine mounts. The rear engine mount can be damaged otherwise.
44	Slightly manually tighten nuts (10)
45	Lift vehicle on vehicle lift
46	Pull out the main assembly lifting table with universal main assembly mount from under the vehicle
	000 588 03 62 00 Lifting platform		WS01.00-P-0091A
		 Adaptation	*453589016200
47	Tighten nuts (10)	 Nut, engine mount to bearing pin	*BA22.10-P-1004-01H
48	Install bracket (13) of refrigerant line (14) at crankcase	Engine 281 in model 453 with code I01 (Air conditioning Plus) Engine 281 in model 453 with code I77 (Air conditioning, manual)
49	Install front engine mount (12) and tighten associated screws		AR22.10-P-4330SR
50	Attach ground line (11) to the transmission housing	 Engine 281 in model 453 with transmission 700.41Bolt, ground line to transmission	*BA27.10-P-1001-06A
		 Engine 281 in model 453 with transmission 700.12Bolt, ground line to transmission	*BA26.00-P-1009-01A
51	Install hydraulic line at clutch slave cylinder and bleed clutch operation	Engine 281 in model 453 with transmission 700.12
			AR25.20-P-1000SR
52.1	Attach shift cables to the transmission	Engine 281 in model 453 with transmission 700.12
			AR26.60-P-6626SR
52.2	Attach cable for selector lever lock to the transmission	Engine 281 in model 453 with transmission 700.41
			AR27.60-P-0002SR
53	Clip in electric line (8) at air filter housing (9) and connect at bleed valve of fuel tank
54.1	Attach vacuum lines (6) to intake manifold (7)	Engine 281.920 in model 453
54.2	Attach vacuum lines (6) to charge air pipe	Engine 281.910 in model 453
55	Attach coolant hoses (25)	Engine 281.910 in model 453
		 Replace clamps.
		 Hose clamp pliers	*003589033700
56	Install coolant hoses (5)	 Replace clamps.
		 Hose clamp pliers	*003589033700
57	Remove protective covers and install air intake hose (4)	 Set of protective covers	*001589039100
58	Remove stop plugs and install fuel line (2) at fuel distributor (3)	 Record plug	*129589009100
59	Install poly-V belt		AR13.22-P-1202SR
60	Install rear axle shafts (18)	Engine 281 in model 453
		Engine 281 in model 453 with transmission 700.12	AR35.30-P-0620SR
		Engine 281 in model 453 with transmission 700.41	AR35.30-P-0620SRA
61	Install control arms		AR35.15-P-0204SR
62	Install rear axle crossmember		AR35.15-P-0250SR
63	Install rear muffler (17)		AR49.10-P-4823SR
64	Clip engine wiring harness (1) into body and guide to installation location of ME-SFI [ME] control unit (N3/10)
65	Install cable tie (19) at engine wiring harness (1)	 Install cable tie (19).
66	Connect all electrical connectors at ME-SFI [ME] control unit (N3/10)		AR07.08-P-7008SR
67	Install ground line (24) and tighten nut (23)	Engine 281 in model 453 with transmission 700.41
		 Nut, battery ground line to body	*BA54.10-P-1004-01I
68	Install ground line (22) and tighten nut (21)	 Nut, battery ground line to body	*BA54.10-P-1004-01I
69	Connect electrical connection (20)
70	Install charge current line		AR15.18-P-0001-01SR
71	Install fuel tank		AR47.10-P-4100SR
72	Fill coolant and bleed cooling system		AR20.00-P-1142SR
		 Only install covering over engine after the leak test.
73	Lower vehicle using vehicle lift and remove vehicle lift safety device		AR00.60-P-0100SR
74	Install fan unit		AR20.40-P-5614SR
		 Only install covering over engine after the leak test.
75	Connect ground lead to battery		AR54.10-P-0003SR
	Check
 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
76	Perform engine test run and check engine as well as transmission for leaktightness
77	Install covering over engine

 Engine mounts, engine supports

Number	Designation		Engine 281 in model 453
BA22.10-P-1004-01H	Nut, engine mount to bearing pin	Nm	62

 Manual transmission, general

Number	Designation		Transmission 700.12
BA26.00-P-1009-01A	Bolt, ground line to transmission	Nm	44

 Automatic transmission complete

Number	Designation		Transmission 700.41
BA27.10-P-1001-06A	Bolt, ground line to transmission	Nm	24

 Battery

Number	Designation		Model 453
BA54.10-P-1004-01I	Nut, battery ground line to body	Nm	21

001 589 03 91 00

Set of protective covers

003 589 03 37 00

Hose clamp pliers

129 589 00 91 00

Record plug

453 589 01 62 00

Adaptation

Powiązane dokumenty

ah0000n000101a Wskazówki dotyczące samozabezpieczających śrub i nakrętek
ah0000p010001a Wskazówki dotyczące napraw komponentów zawieszenia
ah0000p500001a Wskazówki dotyczące zapobiegania uszkodzeniom na skutek zabrudzeń i ciał obcych
ah0110p000101a Obchodzenie się z numerem silnika podczas montażu silników zamiennych i fabrycznie nowych silników zastępczych lub skrzynia korbowej z obudową cylindrów
ah2000n208001a Wskazówki dotyczące płynu chłodzącego
ah5400p000101a Wskazówki dotyczące zapobiegania uszkodzeniom elementów elektronicznych na skutek rozładowania potencjału elektrostatycznego
ar0060p0100sr
ar0110p240006sr
ar0708p7008sr
ar1322p1202sr Demontaż i montaż paska klinowego
ar1518p000101sr
ar2000p1142sr Spuść, napełnij układ płynem chłodzącym.
ar2040p5614sr Demontaż i montaż wentylatora
ar2210p4330sr
ar2210p4330sre Demontaż i montaż przednich łóż silnika
ar2520p1000sr
ar2660p6626sr
ar2760p0002sr
ar3515p0204sr
ar3515p0250sr
ar3530p0620sr
ar3530p0620sra
ar3530p0620sre
ar4710p4100sr
ar4910p4823sr
ar5410p0003sr
ar8355p5310sr
ar8355p5310sre
as0000z000201a Niebezpieczeństwo zranienia skóry i oczy na skutek kontaktu z gorącymi lub żarzącymi się przedmiotami
as0000z000501a Niebezpieczeństwo wypadku na skutek samoczynnego ruszenia przy pracującym silniku. Niebezpieczeństwo obrażeń na skutek zmiażdżenia lub poparzenia przy wykonywaniu czynności podczas rozruchu lub przy pracującym silniku.
as0000z001001a Zagrożenie życia na skutek ześlizgnięcia lub spadnięcia pojazdu z podnośnika.
as0000z001701a Niebezpieczeństwo obrażeńo elementy pojazdu o ostrych krawędziach.
as0040z000101a Niebezpieczeństwo obrażeń skóry i oczu podczas kontaktu z olejem przekładniowym. Zagrożenie dla zdrowia na skutek połknięcia oleju przekładniowego
as1800z000101a Niebezpieczeństwo obrażeń skóry i oczu podczas kontaktu z olejem silnikowym. Niebezpieczeństwo zatrucia wskutek połknięcia oleju silnikowego
as2000z000101a Niebezpieczeństwo zranienia skóry i oczu przez poparzenie wytryskującym, gorącympłynem chłodzącym. Niebezpieczeństwo zatrucia na skutek połknięcia płynu chłodzącego
as4700z000101a Niebezpieczeństwo wybuchu wskutek zapalenia, niebezpieczeństwo zatrucia wskutek wdychania i połknięcia paliwa oraz niebezpieczeństwo obrażeń wskutek kontaktu skóry i oczu z paliwem.
as4900z000101a Niebezpieczeństwo poparzenia, uduszenia i zatrucia podczas prac przy układzie wydechowym i połączonych z nim elementach. Niebezpieczeństwo uduszenia i zatrucia przez wdychanie gazowych i stałych składników spalin. Niebezpieczeństw
ws0100p0091a