Shown on model 212.073 |
2 | Engine covers |
3 | Engine air intake ducts |
4 | Air cleaner housing |
6 | Refrigerant line |
7 | Bulkhead |
8 | Fuel line |
10 | Heater shutoff valve |
11 | Purge line |
12 | Coolant hose |
19 | Vent line |
Y58/1 | Purge control valve |
P01.10-3082-06
P01.10-3083-09
Shown on model 212.073 |
2 | Engine covers | 14 | Vacuum line | 20L | Cooling air line | ||
3 | Engine air intake ducts | 15 | Coolant hose | 20R | Cooling air line | ||
6 | Refrigerant line | 16 | Coolant hoses | 21 | Radiator | ||
7 | Bulkhead | 17 | Coolant hose | 22 | Cold air intake | ||
8 | Fuel line | 18 | Oil lines | 23 | Radiator crossmember | ||
13 | Coolant hose | 19 | Vent line | 39 | Refrigerant line |
Shown on model 207 with code 139 (Measures for engine cooling M157/M278) |
19 | Vent line |
40 | Low-temperature circuit coolant expansion reservoir |
41 | Coolant line |
42 | Coolant hose |
43 | Coolant hose |
44 | Coolant hose |
45 | Coolant expansion reservoir high temperature cooling system |
M13/5 | Coolant circulation pump |
P20.20-2447-06
Shown on model 212.073 |
24 | Torsion bar linkage |
25 | Stabilizer bar |
26 | Brake calipers |
27 | Suspension struts |
28 | Transmission |
29 | Wiring harness |
30 | Steering coupling |
31 | Front axle carrier |
31a | Bolts |
32 | Electrical line |
33 | Bracket |
34 | Cross struts |
35 | Bracket |
36 | Diagonal struts |
37 | Struts |
A80 | Intelligent servo module for DIRECT SELECT |
M42 | Electric oil pump |
P01.10-3084-06
31 | Front axle carrier |
31a | Bolts |
P22.10-2226-06
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. 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. | |
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. | |
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. | |
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 | Protect air conditioning circuit and components from moisture when carrying out repair work | ||
Topical note | Information on preventing damage to electronic components due to electrostatic discharge | ||
Topical note | Notes on coolant | ||
Topical note | Notes on self-locking nuts and bolts | ||
Topical note | Notes on AIRmatic | Model 212 with engine 157, 278 | |
Topical note | Notes on avoiding damage through contamination and foreign objects | ||
Topical note | Notes on bolted connections with self tapping screws | ||
Notes on automatic transmission | |||
Notes on coolant level | |||
General information on work on gasoline direct injection system | |||
Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases | |||
Notes on repair work on suspension components | |||
Notes on safety-relevant components | |||
| Remove/install | ||
1 | Secure vehicle on vehicle lift |
| |
Engine 157, 278 in model 212, 218 | |||
2 | Vent pressure in AIRMATIC system using diagnostic system | Engine 157, 278 in model 212, 218 | |
| |||
3 | Deactivate easy entry/exit feature | Engine 157, 278 in model 212, 218 | |
4 | Turn front wheels to straight-ahead position and fix steering wheel in place with holding device | Retainer device | |
5 | Bring A/T into neutral and release the parking brake | ||
6 | Disconnect ground line from battery | ||
7 | Remove lower engine compartment paneling | ||
Installation: Only install lower engine compartment paneling after leak test. | |||
8 | Drain off coolant |
| |
Engine 157, 278 in model 212, 218 | |||
9.1 | Remove engine covers (2) | Engine 157, 278 in model 212, 218 | |
9.2 | Remove front section of the upper engine cover | Engine 276.9 in model 212.08/28, 218 | |
10 | Drain coolant in low-temperature circuit | Engine 157, 278 in model 212, 218 | |
The drain screw for the low-temperature circuit is located in the low-temperature circuit hose package at the front right in engine compartment. | |||
Installation: The low-temperature circuit coolant expansion reservoir (40) is located under the center engine cover. | |||
11.1 | Remove both engine air intake ducts (3) upstream of the air filter housings (4) | Engine 157, 278 in model 212, 218 | |
11.2 | Remove engine air intake duct upstream of air filter housing | Engine 276.9 in model 212.08/28, 218 | |
12.1 | Remove both air filter housings (4) | Engine 157, 278 in model 212, 218 | |
12.2 | Remove air filter housing | Engine 276.9 in model 212.08/28, 218 | |
Screw/bolt, air filter to air intake pipe support brace | |||
Screw/bolt, air filter to cylinder head cover | |||
13 | Suction off refrigerant out of air conditioning | ||
14 | Disconnect refrigerant line (6) at upper separating point in engine compartment and seal exposed connections with suitable stop plugs | Record plug | |
15 | Remove purge line (11) at purge control valve (Y58/1) and seal exposed connections with suitable stop plugs | Record plug | |
16 | Disconnect vacuum line (14) on bulkhead (7) connecting point and place to one side | ||
17 | Remove coolant hose (12) on heater shutoff valve (10) and bulkhead (7) and remove upwards | ||
18 | Disconnect bleed line (19) at connecting point | Engine 157, 278 in model 212, 218 | |
19 | Disconnect coolant hose (42) from coolant line (41) | Engine 157, 278 in model 212, 218 | |
20 | Disconnect coolant line (43) from distributor below the high-temperature cooling system coolant expansion reservoir (45) | Engine 157, 278 in model 212, 218 | |
21 | Remove coolant hose (44) on the coolant circulation pump (M13/5) | Engine 157, 278 in model 212, 218 | |
22 | Remove coolant hose (13) at coolant pump and radiator (21) and place to one side | ||
23 | Remove coolant hoses (15 ,16) at coolant lines for charge air cooler | Engine 157, 278 in model 212, 218 | |
24 | Detach coolant hose (17) at thermostat housing as well as radiator (21) and remove | Engine 157, 278 in model 212, 218 | |
25 | Remove cold air intake (22) | ||
26 | Fasten cooler (21) to upper radiator crossmember (23) and secure against falling down | ||
27 | Disconnect engine wiring harness on the vehicle side |
| |
Engine 276.9 in model 212.08/28, 218 | |||
Engine 276.9 in model 212.08/28, 218Nut, circuit B+ to alternator | |||
Engine 276.9 in model 212.08/28, 218 with transmission 722.9Bolt, ground line to transmission housing | |||
Engine 276.9 in model 212.08/28, 218 with transmission 722.9Bolt, heat shield to transmission housing | |||
28 | Remove front wheels | ||
| Engine 278 in model 207 | ||
| Engine 157, 278 in model 212, 218 | ||
29 | Remove torsion bar linkage (24) from torsion bar (25) |
| |
Engine 157, 278 in model 212, 218 | |||
The torsion bar (25) remains on the front axle carrier (31). | |||
30 | Remove brake calipers (26) from steering knuckles and secure with connected lines to suspension struts (27) |
| |
Engine 276.9 in model 212.08/28, 218 | |||
Engine 276.9 in model 212.08/28 | |||
Engine 276.9 in model 212.08/28, 218 | |||
Engine 157 in model 212, 218 | |||
31.1 | Remove electric line to intelligent servo module for DIRECT SELECT (A80) and unclip from transmission (28) | Engine 157 in model 212, 218 with transmission 722.9 | |
31.2 | Remove shift rod of range selector lever from transmission (28) | Engine 278 in model 207 with transmission 722.9 | |
32 | Release and disconnect electric line from electric oil pump (M42) and unclip at transmission (28) | ||
33 | Remove heat shield |
| |
Engine 157 in model 212, 218 with transmission 722.9 | |||
Transmission 722.9 in model 207 with engine 278 | |||
34 | Release and disconnect transmission control electrical connector and set down wiring harness (29) outside the working area | ||
35 | Disconnect exhaust system at separating point of center muffler from rear muffler |
| |
Engine 157, 278 in model 212, 218 | |||
36 | Remove steering coupling (30) |
| |
Engine 157, 278 in model 212, 218 | |||
| |||
37 | Disconnect refrigerant line (39) at lower separating point and seal exposed connections with suitable stop plugs | Record plug | |
38 | Remove electric line (32) at rack-and-pinion steering, unclip from front axle carrier (31) and set aside | ||
39 | Disconnect oil lines (18) at separating point and seal exposed connections with suitable stop plugs |
| |
Record plug | |||
40.1 | Remove oil lines from engine oil cooler and seal exposed connections with suitable stop plugs | Engine 157 in model 212, 218 | |
Engine 157 in model 212, 218 | |||
Record plug | |||
40.2 | Disconnect oil lines at separating point from engine oil cooler and seal exposed connections with stop plugs | Engine 157, 278 in model 212, 218 | |
Record plug | |||
41 | Release and disconnect electrical connectors at the front axle distributors | ||
42 | Remove suspension struts (27) from steering knuckles |
| |
Engine 157, 278 in model 212, 218 | |||
43 | Remove brackets (33) of the front level sensor linkage from the cross struts (34) | If installed. | |
| |||
Installation: Replace cable tie. | |||
44 | Remove bracket (35) for the lower engine compartment paneling | ||
45 | Relieve fuel pressure over diagnostic socket | ||
Engine 276.9 in model 212.08/28, 218Cap on service connection | |||
Engine 157, 278 in model 212, 218 | |||
Pressure hose | |||
46 | Remove fuel line (8) at service connection and seal exposed connections with suitable stop plugs | ||
Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | ||
Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | |||
Engine 276.9 in model 212.08/28, 218Union nut, fuel line to service connection | |||
Engine 157, 278 in model 212, 218 | |||
Record plug | |||
47 | Remove struts between right and left side of underbody | Bolt, rear reinforcement brace to frame floor assembly | |
48 | Remove diagonal strut (36) of front axle carrier (31) |
| |
Engine 157, 278 in model 212, 218 | |||
49 | Remove struts (37) of front axle carrier (31) |
| |
Engine 157, 278 in model 212, 218 | |||
50 | Remove coolant lines (20L, 20R) for engine mount | ||
51 | Support front axle carrier (31) with lifting platform and major assembly mount and secure entire engine-transmission unit with a suitable tool against slipping and falling down | ||
| 000 588 03 62 00 Lifting platform | ||
When doing so ensure that mounting plates are evenly aligned. | |||
52 | Remove rear engine crossmember with rear engine mount | ||
53 | Remove propeller shaft from transmission output flange and secure against falling down |
| |
Engine 157, 278 in model 212, 218 | |||
54 | Remove screws (31a) of front axle carrier (31) from longitudinal members | Installation: Replace screw/bolts (31a). | |
Bolt, front axle carrier to longitudinal member | |||
55 | Carefully lower engine transmission unit with front axle carrier (31) | ||
| 000 588 03 62 00 Lifting platform | ||
| |||
56 | Install in the reverse order | ||
| Check | ||
57 | Check engine oil level; correct if necessary | ||
| Engine 276.9 in model 212.08/28, 218 | ||
| Engine 157 in model 212, 218 | ||
| Engine 278 in model 207, 212, 218 | ||
58 | Check transmission oil level and correct if necessary | Engine 157, 278 in model 212, 218 | |
Engine 276.9 in model 212.08/28, 218 with transmission 722.9 (except 722.96) | |||
Engine 157 in model 212, 218 with transmission 722.97 | |||
59 | Perform wheel alignment 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. | |
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. | |
60 | Perform engine test run, as part of this check engine and transmission (28) for proper operation and leak tightness |
129 589 01 21 00
Retainer device
129 589 00 91 00
Record plug
119 589 04 63 00
Pressure hose
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