Remove/install engine with front axle carrier

AR01.10-P-2500OLM

Remove/install engine with front axle carrier

27.07.2020

Engine

654.9 in model 167

Modification notes

12.03.2020

"Pressure release of air suspension" modified.

Operation step 2

12.03.2020

Method sequence for raising vehicle modified.

15.06.2020

Hybrid variant incorporated.

Operation steps 6, 18, 22.2, 30, 35, 59.2, 60, 61, 62, 63

1

Coolant hose

2

Vacuum line

3

Refrigerant line

4

Separation point

5

Vacuum line

6

Coolant hose

7

Coolant line

8

Refrigerant line

10

Coolant hose

11

Coolant line

12

Coolant line

13

Coolant hose

14

Coolant hose

15

Coolant hose

Shown on model 167.117/317

16

Electrical connector

17

Coolant hose

20

Strut

21

Strut

22

Ground cable

23

Fuel hoses

24

Fuel lines

25

Bracket

26

Heat shield

27

Electrical connector

28

Electrical wiring harness

Shown on model 167.117/317

40

High-voltage plug

41

Cable duct

42

Electrical connector

43

Electrical line

44

High-voltage plug

45

High-voltage line

 Danger

Risk of death when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC)

Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines.Engine 654.9 in model 167.117/317

AS00.00-Z-0035-01A

 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. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-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 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

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Topical note

General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment

Engine 654.9 in model 167.117/317

AH00.00-Z-0300-01A

Topical note

Notes on technical cleanliness when working on high-voltage on-board electrical system

Engine 654.9 in model 167.117/317

AH54.00-P-0004-01RFW

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

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 air suspension

AH32.22-P-1000-01T

Notes on handling refrigerant R1234yf

AH83.30-P-0003-02A

Notes on safety-relevant components

Engine 654.9 in model 167.117/317

AH00.00-Z-0019-01A

Notes on automatic transmission

Engine 654.9 in model 167 with transmission 725.0

AH27.19-P-0001-01NKB

Notes about Common-Rail components

AH07.16-P-0002-01TX

Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases

AH01.10-P-0001-01A

 

Remove/install

1

Secure vehicle on vehicle lift.

AR00.60-P-1006A

2

Pump pneumatic pressure of suspension struts using vehicle diagnosis system to central reservoir.

Engine 654.9 in model 167
with code 489 (AIRMATIC)
except code 490 (Electrohydraulic suspension)



AD00.00-P-2000-06ME


The complete wheels must not touch the ground.
Otherwise, the air springs may be pre-damaged and subsequently malfunction.

 Select menu item "Actuations" in active suspension and damping system control unit.

 Installation: Pump pneumatic pressure using vehicle diagnosis system from central reservoir to suspension struts.

3

Put transmission into neutral position.

4

Release parking brake.

5

Move front wheels to straight-ahead position and fix steering wheel in place with holding device.


Do not turn steering wheel with steering coupling removed.
The clock spring contact will otherwise be destroyed.

 Retainer device

*129589012100

6

Remove voltage of high-voltage on-board electrical system.

Engine 654.9 in model 167.117/317

AR47.70-P-1000MEH

7

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

AR54.10-P-0003ME

8

Remove lower engine compartment paneling.

AR61.20-P-1105ME

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

9

Remove underfloor panels.

AR61.30-P-1001ME

 Installation: Install underfloor paneling only after the leak test.

10

Drain off coolant.

AR20.00-P-1142OLM

11

Drain engine oil.

If necessary.



AP18.00-P-0101FM

12

Discharge air conditioning system.

AR83.30-P-1760ME

13

Remove service flaps from engine compartment.

AR01.10-P-2405-02OID

 Nut to wiper arm on front windshield wiper system

*BA82.30-P-1001-01R

14

Remove air filter housing.

AR09.10-P-1150OLM

15

Remove engine air intake duct downstream of air filter.

AR09.10-P-8130OLM

 Installation: Do not install engine cover until after leak test.

16

Remove coolant hose (1) from the firewall and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

17

Remove vacuum line (2) from vacuum line.

18

Remove impact plate.

AR13.22-P-1202OLM

19

Disconnect engine wiring harness.

AR15.18-P-1000-05OLM

 Nut, positive line to engine compartment/vehicle interior prefuse box

*BA54.15-P-1001-01L

20

Remove refrigerant line (3) from connecting point (4), seal connections with suitable stop plugs and protective covers.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Installation: Replace sealing ring and moisten with compressor oil.

 Nut, refrigerant line connecting point

*BA83.30-P-1002-01U

 Set of protective caps

*001589009100

 Assembly tool

*000589936300

 Record plug

*129589009100

21

Fasten refrigerant line (3) to engine.

22.1

Remove refrigerant line (8) from refrigerant compressor with magnetic clutch (A9/7).

Engine 654.9 in model 167 (except 167.117/317)

AR83.55-P-5310OLM

22.2

Remove electrical connector (16), high-voltage plug (44), and refrigerant line (8) from electric refrigerant compressor (A9/5).

Engine 654.9 in model 167.117/317

Remove/install electric refrigerant compressor

AR83.55-P-5311OLR

Detach/attach high-voltage plug

AR47.70-P-0005-01MEH

 Bolt, high-voltage plug to DC charger/high-voltage battery

*BA47.70-P-1006-01C

 Bolt, high-voltage connector to high-voltage power distributor

*BA47.70-P-1001-03B

23

Remove vacuum line (5) and attach it to the engine.

24

Remove coolant hose (6) from coolant line(7) and seal connections with suitable stop plugs.

 Hose clamp pliers

*454589003700

 Record plug

*129589009100

25

Remove coolant hose (14) from coolant line and seal connections with suitable stop plugs.

 Hose clamp pliers

*454589003700

 Record plug

*129589009100

26

Remove coolant hose (15) from the thermostat housing and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

27

Remove the oil cooler from fan unit and attach it to the engine.

Engine 654.9 in model 167 with transmission 725.0

AR27.55-P-1000OID

28

Remove coolant hose (10) from coolant line(11) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589029100

 Set of protective covers

*001589019100

29

Remove coolant hose (13) from coolant line(12) and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

 Set of protective covers

*001589019100

30

Remove coolant hose (17) from coolant line (12), seal with protective covers, and attach to vehicle.

Engine 654.9 in model 167.117/317

AR20.20-P-7441-01RQ

 Set of protective caps

*001589009100

 Set of protective covers

*001589019100

31

Release and disconnect electrical connector from DPF differential pressure sensor (B28/8), remove DPF differential pressure sensor (B28/8) with molded hoses attached, and attach to engine.

AR07.04-P-0025OLM

32

Remove AdBlue® metering valve (Y129) from catalytic converter.

AR49.20-P-2000OLM

33

Release and disconnect electrical connector of left switchable engine mount (Y123) and right switchable engine mount (Y123/1).

AR22.10-P-4330OLM

34

Release and disconnect electrical connectors from power steering actuator motor.

35

Release and disconnect electrical connector at sound generator (H4/16) and at electric vacuum pump (M56), expose wiring harness and attach to vehicle.

Engine 654.9 in model 167.117/317

36

Expose the wiring harness of the electrical power steering and attach it to the vehicle.

37

Remove fuel hoses (23) from fuel lines(24) and collect escaping fuel using suitable container.

 Installation: Install new fuel hoses (23).

 Pliers for click clamps

*171589003700

38

Open holder (25), remove fuel hoses (23), and seal connections with suitable stop plugs.

 Record plug

*129589009100

39

Remove the ground line (22) from the transmission.

 Engine 654.9 in model 167 with transmission 725.0Bolt, ground line to transmission housing

*BA27.10-P-1024-04H

40

Remove exhaust system.

AR49.10-P-7142OID

 Reinstall rear engine carrier and screw in screws.

41

Detach drive shaft from transmission.

AR41.10-P-0050OID

42

Release propeller shaft of the front axle differential from the transfer case.

Engine 654.9 in model 167 with transmission 725.0
If necessary.

AR41.10-P-0070OID

43

Release and disconnect the electrical connector from the transfer case, and expose the electrical line.

Engine 654.9 in model 167 with transmission 725.0

AR28.10-P-0100OID

44

Remove heat shield(26).

 Engine 654.9 in model 167 with transmission 725.0Screw/bolt, heat shield to oil pan

*BA27.10-P-1009-04H

45

Release and disconnect electrical connector(27) and expose electric line.

46

Release and disconnect the electrical connector from the transmission, and expose the electrical wiring harness(28).

47

Remove steering coupling from steering shaft.

AR46.10-P-8000ME

48

Remove front wheel and tire assemblies.

AR40.10-P-1102ME

49

Remove left and right fender liners.

AR88.10-P-1301ME

50

Remove rotational speed sensors from steering knuckles.

AR42.30-P-0713ME

51

Expose electric lines of spring links and steering knuckles.

52

Remove brake calipers with the brake caliper supports and fasten to the vehicle free of tension.

Engine 654.9 in model 167
except code B06 (Silver brake calipers)
except code U29 (AMG high-performance braking system)
except code U70 (red-painted brake callipers)

Engine 654.9 in model 167
except code B06 (Silver brake calipers)
except code U29 (AMG high-performance braking system)
except code U70 (red-painted brake callipers)

AR42.10-P-0070ME

53

Remove steering knuckles from upper transverse control arms.

AR33.25-P-0400ME


Secure the steering knuckle again folding away.
Non-observance damages the joints.

54

Remove suspension struts from bottom lower control arms.

Engine 654.9 in model 167
except code 489 (AIRMATIC)
except code 490 (Electrohydraulic suspension)
Engine 654.9 in model 167
with code 489 (AIRMATIC)
except code 490 (Electrohydraulic suspension)

AR32.25-P-1017ME

55

Support front axle carrier with lifting platform.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

56

Secure engine transmission unit against slipping and falling down with tensioning strap.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

57

Remove rear engine carrier from frame floor assembly.

AR22.10-P-4360OID

 The rear engine support remains on the transmission.

58

Remove struts (20, 21).

AR33.10-P-0100ME

59.1

Lower engine transmission unit with front axle carrier.

Engine 654.9 in model 167 (except 167.117/317)



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with front axle carrier.
Otherwise damage will occur.

 Aid of helper required.

59.2

Lower engine transmission unit with front axle carrier until high-voltage plug (40) is accessible.

Engine 654.9 in model 167.117/317



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with the front axle carrier.
Otherwise damage will occur.

 Aid of helper required.

60

Release and disconnect electrical connector (42), seal openings with protective covers, and expose electric line (43).

Engine 654.9 in model 167.117/317

 Set of protective caps

*001589029100

61

Release and disconnect high-voltage plug (40), seal connections with protective covers, and expose cable duct (41).

Engine 654.9 in model 167.117/317

AR47.70-P-0005-01MEH


Handle high-voltage plug (40) with care.
Otherwise the high-voltage on-board electrical system may be damaged.

 Bolt, high-voltage plug to DC charger/high-voltage battery

*BA47.70-P-1006-01C

 Bolt, high-voltage connector to high-voltage power distributor

*BA47.70-P-1001-03B

 Set of protective covers

*001589039100

62

Expose high-voltage line (45).

Engine 654.9 in model 167.117/317


Handle high-voltage plug (40) with care.
Otherwise the high-voltage on-board electrical system may be damaged.

63

Carefully lower engine transmission unit with the front axle carrier.

Engine 654.9 in model 167.117/317



000 588 03 62 00 Lifting platform

WS01.00-P-0091A


Carefully lower engine transmission unit with the front axle carrier.
Otherwise damage will occur.

 Aid of helper required.

64

Fasten steering knuckles with a tensioning strap to the engine.

65

Install in the reverse order.

Concluding tasks

66

Perform chassis alignment.

AR40.20-P-0200ME

67

Read out and delete fault memory.



AD00.00-P-2000-06ME

68

Calibrate Distance Pilot DISTRONIC controller unit.

Engine 654.9 in model 167
with code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
Engine 654.9 in model 167
with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))



AD00.00-P-2000-06ME

69

Check engine oil level and correct if necessary.



AP18.00-P-1812SKI

 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

 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

70

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Automatic transmission complete

Number

Designation

Transmission 725.0/1

BA27.10-P-1009-04H

Screw/bolt, heat shield to oil pan

Nm

9

 Automatic transmission complete

Number

Designation

Transmission 725.0/1

BA27.10-P-1024-04H

Bolt, ground line to transmission housing

Nm

20

 High-voltage power distributor

Number

Designation

Model 167
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA47.70-P-1001-03B

Bolt, high-voltage connector to high-voltage power distributor

Nm

4

 High-voltage battery

Number

Designation

Model 167
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA47.70-P-1006-01C

Bolt, high-voltage plug to DC charger/high-voltage battery

Nm

4

 Fuse and relay box

Number

Designation

Model 167

BA54.15-P-1001-01L

Nut, positive line to engine compartment/vehicle interior prefuse box

M6

Nm

8

M8

Nm

16

 Windshield wiper

Number

Designation

Model 167

BA82.30-P-1001-01R

Nut to wiper arm on front windshield wiper system

Nm

30

 Air conditioning

Number

Designation

Model 167

BA83.30-P-1002-01U

Nut, refrigerant line connecting point

M6

Nm

12

M8

Nm

20