Shown on model 205 without code ME05 (hybrid drive 85 kW – 94 kW – variant (incl. plug-in)) |
1 | Bolts |
3 | Propeller shaft |
5 | Exhaust system |
6 | Fuel hose |
7 | Fuel hose |
8 | Fuel line |
9 | Fuel line |
P01.10-3327-06
Shown on model 205 without code ME05 (hybrid drive 85 kW – 94 kW – variant (incl. plug-in)) |
17 | Electrical wiring harness |
18 | Bracket |
19 | Vacuum line |
20 | Coolant hose |
21 | Coolant line |
22 | Coolant line |
P01.10-3329-06
Shown on model 205 with code ME05 (hybrid drive 85 CKA-94 CKA – variant (incl. plug-in)) |
22 | Coolant line |
23 | Coolant line |
24 | Charge air cooler |
32 | Coolant hose |
P01.10-A112-05
Shown on model 205 without code ME05 (hybrid drive 85 kW – 94 kW – variant (incl. plug-in)) |
28 | Fitting |
29 | Coolant pipe |
30 | Coolant pipe |
32 | Coolant hose |
33 | Coolant hoses |
P20.20-A033-05
Shown on model 205 with code ME05 (hybrid drive 85 CKA-94 CKA – variant (incl. plug-in)) |
34 | Ground cable |
35 | Electrical connector |
36 | Electrical connector |
37 | Heat shield |
P01.10-A113-06
P01.10-A005-09
Shown on model 205 with code ME05 (hybrid drive 85 CKA-94 CKA – variant (incl. plug-in)) |
40 | High-voltage connection | 42 | Cable duct of high voltage lines | 44 | High-voltage connection | ||
41 | Shield | 43 | Equipotential bonding line | 47 | 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 in model 205 | |
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. | |
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. | |
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. | |
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. | |
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. | |
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. | |
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. | |
Topical note | General information on handling vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system | Engine 654 in model 205 | |
Topical note | Notes on coolant | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Procedure for a damaged or leaky air conditioning system | ||
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on bolted connections with self tapping screws | ||
Topical note | Notes on self-locking nuts and bolts | ||
Notes on safety-relevant components | |||
Notes on automatic transmission | Engine 654 in model 205, 253 with transmission 725.0 | ||
Notes about Common-Rail components | |||
Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases | |||
| Remove/install | ||
1 | Secure vehicle to prevent it moving away. | ||
2 | Put transmission into neutral position. | ||
3 | Release parking brake. | ||
4 | Deactivate easy entry and exit feature for steering wheel in instrument cluster. | ||
5 | Move front wheels to straight-ahead position and fix steering wheel in place with holding device. | Retainer device | |
6 | Perform power disconnect of high-voltage on-board electrical system. | Engine 654 in model 205.013/213 | |
7 | Clamp off ground line from the on-board electrical system battery (G1). | ||
8 | Secure vehicle on vehicle lift. | ||
9 | Remove upper engine cover. | ||
Installation: Only install upper engine cover after the leak test. | |||
10 | Remove lower engine compartment linings. | ||
Installation: Do not install lower engine compartment linings until after leak test. | |||
11 | Drain engine oil. | ||
| Engine 654 in model 205, 253 | ||
| Engine 654 in model 205, 253 | ||
Use a clean container where engine oil will be reused. | |||
12 | Drain coolant at radiator. |
| |
Engine 654 in model 205 | |||
13.1 | Drain coolant from low-temperature circuit. | Engine 654 in model 253 | |
13.2 | Drain coolant from the auxiliary circuit. | Engine 654 in model 205.013/213 | |
14 | Remove equipotential bonding line (43) from transmission. | Engine 654 in model 205 | |
Engine 654 in model 205.013/213 | |||
15 | Support the transmission. | Engine 654 in model 205 | |
| 000 588 10 62 00 Support plate | ||
| 000 588 11 62 00 Major assembly mount | ||
16 | Remove rear engine carrier from frame floor assembly. | Engine 654 in model 205 | |
17 | Lower transmission slightly. | Engine 654 in model 205 | |
| 000 588 11 62 00 Major assembly mount | ||
| |||
18 | Remove cable duct of high voltage lines (42) from transmission. | Engine 654 in model 205 | |
Bolt, hoop guard to transmission | |||
19 | Remove shield (41) over high-voltage plug(40). | Engine 654 in model 205 | |
20 | Release and disconnect high-voltage plug (40) of the electric machine, place cable duct for high-voltage lines (42) to one side, and seal connections with suitable protective covers. | Engine 654 in model 205 | |
| |||
Bolt, 3-phase high-voltage line coupling connector to electrical machine housing | |||
Set of protective caps | |||
21 | Lift transmission and install rear engine carriers at frame floor assembly. | Engine 654 in model 205 | |
22 | Remove front engine mounts from the engine carriers. | ||
23 | Unscrew screws (1) of the rear engine mount at the engine carrier. | ||
24 | Detach propeller shaft (3) from transmission. |
| |
Engine 654 in model 205 | |||
25 | Remove fuel hoses (6, 7) at fuel lines (8, 9) and collect escaping fuel with suitable container. | Installation: Install new fuel hoses (6, 7). | |
Pliers for click clamps | |||
26 | Close off openings of the fuel hoses (6, 7) and fuel lines (8, 9) using suitable stop plugs. | Record plug | |
27 | Remove steering coupling. | ||
| |||
28 | Remove coolant hoses from circulation pump. | ||
29 | Remove air filter housing. | ||
30 | Remove engine air intake duct downstream of air filter. | ||
31 | Disconnect engine wiring harness. | ||
Nut, positive line to busbar on firewall | |||
32 | Remove ground line (34) from the underbody. | Engine 654 in model 205 | |
Nut, ground line to pin/underfloor | |||
33 | Remove heat shield (37) and release and disconnect electrical connector (36). | Engine 654 in model 205 | |
34 | Release and disconnect electrical connector (35). | Engine 654 in model 205 | |
35 | Unclip electrical wiring harness (17) from bracket (18). | ||
36 | Remove vacuum line (19) at bulkhead. | ||
37 | Seal connection of the vacuum line (19) and bulkhead with suitable protective covers. | | |
Set of protective covers | |||
38 | Remove coolant hose (20) at bulkhead. | ||
39.1 | Remove coolant lines (21, 22) at expansion reservoir. | Engine 654 in model 205 | |
39.2 | Remove coolant lines (21, 22) from the shutoff valve of the low-temperature circuit. | Engine 654 in model 205 | |
40 | Remove coolant line (22) at cooler. | ||
41 | Firmly connect coolant lines (21, 22) to engine. | ||
42 | Disconnect coolant line (23) on the charge air cooler (24). | ||
43 | Remove DPF differential pressure sensor (B28/8) and place on the engine with connected molded hoses. | ||
44 | Remove fan unit. |
| |
Engine 654 in model 205 | |||
45 | Mount protective plate on cooler. | ||
| |||
46 | Remove poly-V-belt. | ||
47 | Remove AdBlue® metering valve (Y129) from the catalytic converter and place to one side with connected lines. | ||
48 | Remove coolant hoses from low-temperature circuit(M43/7) circulation pump 2. | ||
49 | Expose coolant pipe (30) and remove. | ||
Bolt, coolant line for cooler/coolant pump to carrier for A/C compressor | |||
50 | Remove coolant pipe (29) from fitting (28). | ||
51 | Remove coolant hoses (33) from coolant hose (32). | ||
52 | Release and disconnect high-voltage plug (44) and remove high-voltage line (47) from the charge-air distributor. | Engine 654 in model 205 | |
53 | Remove refrigerant compressor (A9) and electrical refrigerant compressor (A9/5), place to one side with connected refrigerant lines and secure against falling down. | Electrical refrigerant compressor (A9/5) | |
Refrigerant compressor (A9)Engine 654 in model 205, 253 | |||
54 | Hook load tilter and engine crane into all engine lifting lugs. | ||
| 000 588 00 62 00 Load tilter | ||
Commercially available devices/tools | |||
55 | Lower engine with transmission to the rear and lift out. | ||
| 000 588 00 62 00 Load tilter | ||
| |||
Aid of helper required. | |||
Commercially available devices/tools | |||
56 | Install in the reverse order. | ||
Concluding tasks | |||
57 | Check engine oil level and correct if necessary. | ||
| |||
58 | Connect vehicle diagnosis system, read out fault memory and clear if necessary. | ||
| |||
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. | |
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. | |
59 | Perform engine test run; while doing so, check engine with transmission for proper operation and leak tightness. | ||
60 | Install engine compartment linings. | ||
61 | Install upper engine cover. |
171 589 00 37 00
Pliers for click clamps
129 589 01 21 00
Retainer device
129 589 00 91 00
Record plug
001 589 01 91 00
Set of protective covers
001 589 02 91 00
Set of protective caps
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