Remove/install engine with front axle carrier

AR01.10-L-2500VB

Remove/install engine with front axle carrier

1.2.08

22.1.02

Value changed from 120 Nm to 110 Nm

Value in series BA33.10-P-1001-01B for models 414.600/700 modified

 

Remove/install

Danger!

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

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

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Remove front wheels



Remove/install wheels, rotate if necessary

AP40.10-P-4050Z

2

Disconnect battery ground line

AR54.10-P-0003A

3.1

Unscrew oil drain screw from oil pan at automatic transmission and drain ATF

 Installation: Install new sealing ring.

 Only on vehicles with automatic transmission.



*BA27.10-P-1001-03A

4

Drain coolant

 At radiator and at crankcase.

AR20.00-L-1142VA

5

Remove front bumper.

AR88.20-L-2000VA

6

Separate plug connection (60) to outside temperature display temperature sensor (B14)

 Ensure plug connection (60) is correctly seated.

7

Remove washer fluid reservoir

 Twist locking lever and lift washer fluid reservoir.

Use a screwdriver to press the washer fluid pump off the washer fluid reservoir with lines connected.

8

Detach air intake scoop (1) and air intake duct (3) from front end cross member (2)

9

Remove air filter housing (5).

AR09.10-L-1050VB

10

Detach vacuum line (4) at intake manifold

11

Detach connector of vehicle wiring harness (9) at engine control unit with integrated throttle valve actuator (N3/18)

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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

12

Disconnect fuel line (12) at fuel distributor

 Seal fuel line (12) with a suitable plug.

13

Detach vacuum line (16) at purge control valve (Y58/1)

14

Detach air hose (11) at air pump (M33)

Opened hose clamps must be checked for any visible damage and replaced if necessary.

15

Detach coolant hose (14) at coolant pipe

16

Detach coolant hose (18) at coolant thermostat

17

Detach coolant hose (37) to heat exchanger at firewall

18

Detach coolant hose (21) from heat exchanger at thermostat housing

19

Attach radiator (24) with cable or cord to front end cross member (2)

 Radiator (24) is secured to prevent it dropping down.

20.1

Detach ATF lines (10) at oil cooler and seal with suitable plug

 On models fitted with automatic transmission.

The oil cooler is integrated within the radiator.



*BA20.20-P-1002-01C



*129589009100

21

Turn steering wheel into middle position, withdraw ignition key and engage steering lock

22

Remove bolt (44) and detach steering coupling (41) at the steering shaft (42), take off thrust piece (43)

 Installation: Install new nut holder (45).



*BA46.10-P-1002-01C

23

Disconnect ground cable from left front engine support

24

Detach ground cable at right front longitudinal frame member

25

Disconnect positive line (63) and control line (64) for power steering pump at left frame longitudinal member

 Expose cables, replace clips attaching cables below terminal point.

26.1

Turn clamping nuts (arrows) in anti-clockwise direction. Detach gear selection shift cable (35) and gate selection shift cable (36) from the bracket

 On vehicles with manual transmission.

27.1

Unclip gear selection shift cable (35) and gate selection shift cable (36) from the ball head

 On models fitted with manual transmission.

Installation: Gear selection shift cable (35) and gate selection shift cable (36) have to be properly locked in the ball head.

28.1

Separate plug connection (65) to backup lamp switch (S16/2)

 On vehicles with manual transmission.

Installation: Pay attention to the correct position of the connector (65).

29.1

Unplug connectors from selection direction turning angle sensor (B54/1) and shift direction turning angle sensor (B54).

 On models fitted with automatic clutch actuation (code GS5).

Installation: Pay attention to the correct position of the connector.

30.1

Detach wiring harness of turning angle sensors (B54 and B54/1) at the manual transmission, and expose

 Replace cable ties.

31.1

Unscrew bolt (28) from bracket (29)

 On models fitted with automatic transmission.



*BA27.10-P-1002-04B

32

Remove bolts (50) and detach suspension strut (51) at spring tower

 Installation: Insert the guide pins (arrows) in the spring tower.



*BA32.25-P-1002-04A

33

Unscrew bolts (53).

Detach floating caliper (52) at steering knuckle and tie up in wheel well together with brake pads, and with brake hose connected

 Installation: Replace bolts (53).



*BA42.10-P-1001-03B

34

Unclip brake pads contact sensor (S10/2) and cable of left front axle wheel speed sensor (L6/1), cable of right front axle wheel speed sensor (L6/2) at suspension strut (51), and expose cables

 Brake bad contact sensor (S10/2) is installed only at front right.

35

Take out screws (61) and remove cover (62) on left and right at front axle carrier (46)

36

Remove right front underfloor paneling

AR94.30-L-5300VA

 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

37.1

Remove locking element (33) and pull clutch hose (32) out of the transmission

 Seal clutch hose (32) with a suitable plug.

 Only on models fitted with manual transmission.

Installation: Replace fuse (33) and sealing ring (34).



Brake fluid notes

All models

AH42.50-P-0001-01A



*129589009100

38

Use a suitable tool to detach retaining clamp (25) and separate exhaust system (26) at the connection point

 Inspect retaining clamp (25), replace if necessary.

39

Take cable of O2 sensor downstream of TWC (G3/1) out of retaining clip (arrow) at underfloor and separate plug connection at underfloor

40

Unscrew bolts (57). Detach wiring harness together with bracket and ground cable (56) at oil pan

41.1

Slacken poly-V belt (58) and take it off at refrigerant compressor (A9)

 Vehicles with air conditioning.

(code H06).

AR13.22-P-1202GF

42

Remove fender liners from underfloor on left and right sides and fold down

 To gain access to the rear bolts (47).

43.1

Detach bracket for AC line at rear right of front axle carrier (46)

 On models fitted with air conditioning (code H06).

44.1

Remove bolts attaching refrigerant compressor (A9). Take off refrigerant compressor (A9) and attach to underfloor with cables and refrigerant lines connected

 Do not separate refrigerant hoses.

 Only on models fitted with air conditioning

(code H06).

45

Unscrew bolts (49) of strut (48) on left and right at front axle carrier (46) and at underfloor and take off strut (48)



*BA33.10-P-1003-01B

46

Position removal fixture of front axle carrier (59) at front axle carrier (46)

47

Turn out screws (47) on both sides

 Installation: First fit all the bolts (47), then tighten.



*BA33.10-P-1001-01B

48

Carefully lower engine together with front axle carrier (46) far enough to gain access to starter (M1) and alternator (G2)

 Proceed with caution to avoid damaging coolant hoses, AC hoses and electrical wiring.

Installation: Guides (arrow) on the front-axle carrier (46) must be inserted into the holes in the longitudinal member.

Guides of the suspension struts (51) must be inserted into the holes in the suspension strut dome (arrows).

49.1

Detach selector range cable (31) at the shift linkage

On models fitted with automatic transmission.

50.1

Pull bracket (29) at automatic transmission out of the mount (arrow)

On models fitted with automatic transmission.

51.1

Separate electrical plug connection (30) at transmission and expose cable

 On models fitted with automatic clutch actuation (code GS5) or on models fitted with automatic transmission.

52

Detach wiring harness (55) at starter (M1)

 Terminal 50

*BA15.30-P-1002-01B

 Terminal 30

*BA15.30-P-1003-01B

53

Detach wiring harness (54) at alternator (G2)

 Ensure plug connection is correctly seated.

*BA15.40-P-1001-01B

 Circuit B+

*BA15.40-P-1002-01B

54

Carefully lower the engine with front axle carrier (46) fully

 Proceed with caution to avoid damaging coolant hoses, a/c hoses and electrical wiring.

55

Install in the reverse order

 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.
Always wear appropriate work clothing when working on the vehicle.

AS00.00-Z-0005-01A

56

Check for leaks with engine running

57

Inspect ATF level in transmission, pour in ATF if necessary

 On models fitted with automatic transmission.

AR27.00-P-0101GC

58

Bleed clutch operating system

AR25.20-L-0070VA

59

Inspecting cooling system for leaks

AR20.00-L-1010VA

60

Read out fault memory



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
166.961/
991

BA15.30-P-1002-01B

Cable to starter circuit 50

Nm

6

BA15.30-P-1003-01B

Cable on starter circuit 30

Nm

9

Number

Designation

Engine 166.961/
991

BA15.40-P-1001-01B

Cable to alternator terminal D+

Nm

8

BA15.40-P-1002-01B

Cable to alternator terminal B+

Nm

18

Number

Designation

Engine 166.961/
991

BA20.20-P-1001-01C

Bolt, coolant line to crankcase

Nm

8

Number

Designation

Engine 166.961/
991

BA20.20-P-1002-01C

Union nut, automatic transmission oil line to radiator

Nm

25

Number

Designation

Trans-mission 722.3

Trans-mission 722.4/5/7

BA27.10-P-1001-03A

Drain plug on transmission oil pan

Nm

14

22

Number

Designation

Transmission 722.750/751
in model 414

BA27.10-P-1002-04B

Bolt, range selector cable bracket to transmission

Nm

8

Number

Designation

Model 414

BA32.25-P-1002-04A

Bolt, suspension strut to suspension strut dome

Nm

40

Number

Designation

Model
414.700

BA33.10-P-1001-01B

Bolt, front-axle carrier to body

M 12

Nm

110

BA33.10-P-1003-01B

Strut bolt on front-axle carrier
and body

M 10

Nm

50

Number

Designation

Model 414

BA42.10-P-1001-03B

Self-locking nut, floating caliper to steering knuckle

Nm

115

Number

Designation

Model 414

BA46.10-P-1002-01C

Bolt, steering coupling to steering shaft

Nm

20