Remove/install engine

AR01.10-P-2400MC

Remove/install engine

17.4.08

 

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

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

AS00.00-Z-0013-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Remove transmission

AR27.10-P-0500I

2

Drain coolant at radiator

AR20.00-P-1142H

3

Drain coolant for low-temperature circuit

AR20.00-P-1142HM

4

Extract/drain engine oil



Engine oil and filter change

AP18.00-P-0101H

5

Remove left air filter housing (1)

AR09.10-P-1150LA

6

Remove poly-V belt

AR13.22-P-1202L

7

Remove vacuum line (2) to purge control valve

8

Remove coolant expansion reservoir (3) for coolant

9

Disconnect coolant hose (4) at alternator (G2)

 Inspect condition of coolant hose and hose clamp, replace if necessary.

10

Remove coolant hose (5) from thermostat to radiator and additional radiator

 Check condition of coolant hose, O-ring, clamp and hose clamps, replace if required.

11

Disconnect both coolant hoses (6) of low temperature circuit from radiator pipe

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

12

Remove coolant hose (7) from coolant pump to radiator, expansion reservoir (3) and additional radiator

 Check condition of coolant hose, O-ring, clamp and hose clamp, replace if required.

13

Disconnect line to additional radiator

14

Disconnect heater hose (8)

 Check condition of heater hose and clamp, replace if required.

15

Suction off hydraulic fluid from oil reservoir (9) of power steering pump

 The oil reservoir of the power steering pump and ABC oil reservoir form one unit and cannot be separated.

 Hand pump

*210589007100

16

Suction off hydraulic fluid out of ABC oil reservoir (9)

 Hand pump

*210589007100

17

Unplug plug (10) of power steering pump throttle valve

18

Detach ground cable (11) of power steering pump at body

19

Disconnect feed line (12) of power steering pump at oil reservoir (9) of power steering pump

 Seal the connections.

 Check condition of hose clamp and feed line (12) and replace if necessary.

 Set of plugs

*129589009100

20

Disconnect feed line (13) of Active Body Control at oil reservoir (9) of Active Body Control

 Seal the connections.

 Check condition of hose clamp and feed line (13) and replace if necessary.

 Set of plugs

*129589009100

21

Disconnect return line (14) of power steering pump at oil reservoir (9) of power steering pump

 Seal the connections.

 Check condition of hose clamp and return line (14) and replace if necessary.

 Set of plugs

*129589009100

22

Disconnect ABC return line (15) from ABC oil reservoir (9)

 Seal the connections.

 Check condition of hose clamp and return line (15) and replace if necessary.

 Set of plugs

*129589009100

23

Disconnect electrical connector (16) from brake system hydraulic unit

24

Unscrew nuts (19) and remove oil reservoir (9)

25

Detach hydraulic line (17) of power steering at power steering pump

 Seal the connections.

 Installation: Install new O-ring.

 Set of plugs

*129589009100



*BA46.30-P-1003-01C

26

Remove banjo bolt (18) of pressure line for Active Body Control at power steering pump

 Seal the connections.

 Installation: Install new O-ring.

 Set of plugs

*129589009100



*BA46.30-P-1012-01C

27

Remove bolts (20) of oil cooler line (21) at crankcase

 Installation: Install new O-ring.



*BA18.30-P-1004-01B

28

Separate electrical connector (A9x1) of refrigerant compressor (A9)

29

Remove bolts (22) for refrigerant compressor (A9)

 Place refrigerant compressor (A9) with connected lines to the side in engine compartment.



*BA83.55-P-1001-01A

30

Disconnect hydraulic line (17) of power steering at hydraulic hose (23) and detach from crankcase

 Hydraulic line remains in engine compartment.



*BA46.30-P-1017-01C

31

Remove banjo bolt (24) of Active Body Control hydraulic line at valve unit of pressure supply

 Seal the connections.

 Installation: Install new O-ring.

 Set of plugs

*129589009100



*BA32.50-P-1017-01A

32

Detach right oil cooler line (25) at oil cooler

 Seal the connections.

 Set of plugs

*129589009100



*BA18.30-P-1003-01B

33

Disconnect transmission oil line (26) at radiator

 Seal the connections.

 Set of plugs

*129589009100



*BA20.20-P-1001-01A

34

Disconnect engine wiring harness

AR15.18-P-1000-02MC

35

Detach vacuum line (27) of brake booster at rear intake manifold

 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

36

Disconnect fuel hose (28) at fuel line

 Release fuel pressure through service valve.

 Pressure hose

*119589046300



*BA07.52-P-1002-01E

37

Mount rear lifting eye onto engine

 Lifting eye

*285589016100

38

Attach engine hoist to engine lifting eyes

Engine hoist

39

Unscrew bolts (29) of front engine mounts at front axle carrier



*BA22.10-P-1001-01L

40

Lift out engine

 Ensure, when lifting out engine that no cables and lines are damaged and that engine does not lean against firewall.

Engine hoist

41

Install in the reverse order

42

Fill and bleed active body control (ABC)

AR32.50-P-0021N

43

Fill power steering pump and bleed

AR46.30-P-0010N

44

Inspecting cooling system for leaks

AR20.00-P-1010HA

Danger!

Risk of accident due to vehicle starting off 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

45

Check for leaks with engine running

46

Read out fault memory with STAR DIAGNOSIS and erase if necessary

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine
275, 285

BA07.52-P-1002-01E

Union nut connecting fuel feed line to fuel distributor

Nm

20

Number

Designation

Engine
275.950/
951/953/
954, 285

BA18.30-P-1003-01B

Union nut, oil line to oil cooler

Nm

30

BA18.30-P-1004-01B

Oil line to crankcase

Nm

8

Number

Designation

Engine
275

BA20.20-P-1001-01A

Union nut, automatic transmission oil line to radiator

Nm

25

Number

Designation

Engine
275.950/980
in model 220

Engines
275.950/
980
in model 215

BA22.10-P-1001-01L

Bolt, front engine mount to front axle carrier

Nm

35

35

Number

Designation

Model
215

Model
220

BA32.50-P-1017-01A

Banjo bolt on pressure supply valve unit

Nm

40

40

Number

Designation

Model
215.376/379, 220.176/179
with code 487a

BA46.30-P-1003-01C

High-pressure expansion hose to power steering pump

M141.5

Nm

-

M161.5

Nm

40

BA46.30-P-1012-01C

Banjo bolt, high pressure expansion hose (Active Body Control) to power steering pump

Nm

40

BA46.30-P-1017-01C

Union nut, high pressure hose to power steering pump high-pressure line

Nm

40

Number

Designation

Engine
275
in model
215, 220, 230

BA83.55-P-1001-01A

Bolt, refrigerant compressor to bracket

Nm

20