Remove/install engine with front axle carrier

AR01.10-P-2500OLI

Remove/install engine with front axle carrier

06.12.2019

Engine

654 in model 205, 253

with code M005 (Vehicles with 4MATIC/all-wheel drive)

Modification notes

24.10.2019

Document completely revised.

Operation steps 1 to 67

Shown on model 205

1

Coolant hose

2

Vacuum line

3

Vacuum line

4

Refrigerant line

5

Refrigerant line

6

Separation point

7

Coolant hose

8

Reinforcement

9

Vent line

10

Injection line

11

Coolant hose

Shown on model 253.311

12

Coolant hoses

13

Suction pipe

Shown on model 205.0

15

Strut

20

Fuel lines

B12

Refrigerant pressure sensor

17

Coolant hose

22

Diagonal strut

M91/6

Heater circuit circulation pump

19

Fuel hoses

A91m1

Electric power steering actuator motor

Shown on model 205.4 left side

23

Strut

24

Bolts

Shown on model 253.311

30

Power distributor

HV1

High-voltage line

HV2

High-voltage line

HV3

High-voltage line

Shown on model 253 with code ME05 (hybrid drive 85 kW – 94 kW – variant (incl. Plug-in))

34

Ground cable

35

Electrical connector

36

Electrical connector

37

Heat shield

 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 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

AS00.00-Z-0035-01A

 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.

AS00.00-Z-0010-01A

 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. 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 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.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 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.
Do not pour transmission oil into beverage bottles.

AS00.40-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

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 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

AH00.00-Z-0300-01A

Topical note

Notes on coolant

AH20.00-N-2080-01A

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

Notes on AIRmatic

Engine 654 in model 205
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 654 in model 253
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AH32.22-P-1000-02LW

Notes on safety-relevant components

AH00.00-Z-0019-01A

Notes on automatic transmission

Transmission 725.0 in model 205, 253 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)

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

Reduce pressure of air suspension.

Engine 654 in model 205
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 654 in model 253
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)



AD00.00-P-2000-04B

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

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.
Clock spring contact will otherwise be destroyed.

 Retainer device

*129589012100

6

Perform power disconnect of high-voltage on-board electrical system.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

AR54.10-P-1150LVH

7

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

AR54.10-P-0003LW

8

Remove lower engine compartment paneling.

AR61.20-P-1105LW

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

9

Drain off coolant.

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR20.00-P-1142OLG

Engine 654 in model 205
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR20.00-P-1142OLI

10

Drain coolant from low-temperature circuit.

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR20.00-P-1144OLG

11

Drain coolant from the auxiliary circuit.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

AR08.50-P-0022OLG

12

Discharge air conditioning system.

AR83.30-P-1760LW

13

Remove air filter housing.

AR09.10-P-1150OLI

14

Remove coolant hose (1) from firewall.

AR20.20-P-7441-01RQ

15

Disconnect coolant hoses (12), remove from the auxiliary circuit expansion reservoir, and fasten to the engine.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

 Hose clamp pliers

*454589003700

16

Remove vacuum line (2) from vacuum line (3).

17

Remove refrigerant lines (4, 5) from the separating point (6) and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

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

 Nut, refrigerant line to connecting point

*BA83.30-P-1004-01Q

 Assembly tool

*000589936300

 Record plug

*129589009100

18

Remove suction line (13).

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

19

Disconnect engine wiring harness for removal of the engine.

AR15.18-P-1000-05OLI

 Nut, positive line to busbar on firewall

*BA54.18-P-1001-02C

20

Remove ground line (34) from the underbody.

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Nut, ground line to pin/underfloor

*BA00.19-P-1043-01E

21

Remove heat shield (37) and release and disconnect electrical connector (36).

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

22

Release and disconnect electrical connector (35).

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

23

Remove expansion reservoir.

AR20.30-P-4950LW

24

Remove air intake connection.

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Dismantling tool

*000589956300

25

Remove reinforcement (8).

 Screw, front module carrier/cross strut to body/angle bracket for front module carrier

*BA62.30-P-1007-01H

 Bolt, lock striker to cross member/front-module carrier

*BA62.30-P-1008-01H

26

Remove coolant hose (7) from the low-temperature circuit cooler and seal openings with protective covers.

AR20.20-P-7441-01RQ

 Set of protective covers

*001589019100

27

Remove refrigerant line (5) from condenser and seal openings with suitable stop plugs.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

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

 Nut, line to condenser

*BA83.30-P-1002-01Q

 Assembly tool

*000589936300

 Record plug

*129589009100

28

Release and disconnect electrical connection from fan unit.

29

Fix bleed line (9) in place on engine.

30

Remove injection line (10) from the AdBlue® metering valve (Y129).

AR49.20-P-2000OLI

31

Fasten coolant hose (11) to the engine.

32

Release and disconnect electrical connector from refrigerant pressure sensor (B12).

33.1

Remove struts (15) from damping.

Engine 654 in model 205 (except 205.4), 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

33.2

Remove struts (23).

Engine 654 in model 205.4
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Bolt, strut to cross member

*BA62.30-P-1003-01H

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

34

Remove screws (24).

Engine 654 in model 205.4
with code M005 (Vehicles with 4MATIC/all-wheel drive)

 Bolt, strut to soundproofing

*BA62.30-P-1004-01H

35

Release and disconnect electrical connector from the low-temperature circuit temperature sensor (B10/13).

AR09.41-P-6931OLI

36

Remove coolant lines from low-temperature circuit 1 circulation pump (M43/6) and seal openings with suitable protective covers.

AR09.41-P-6931OLI

 Set of protective covers

*001589019100

37

Release and disconnect electrical connector from the heating circuit circulation pump (M91/6).

38

Remove coolant hose (17) from the heating circuit circulation pump (M91/6) and seal openings with suitable protective covers.

 Hose clamp pliers

*454589003700

 Set of protective covers

*001589019100

39

Release and disconnect electrical connectors from the electric power steering actuator motor (A91m1).

40

Unclip wiring harness of electric power steering from front axle carrier.

 Dismantling tool

*000589956300

41

Release and disconnect high-voltage lines (HV1, HV2) from the electricity distributor (30).

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

42

Remove high-voltage line (HV3) from the front-end assembly and fasten to the engine using suitable means.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

43

Remove fuel hoses (19) from fuel lines(20) and collect escaping fuel using suitable container.

 Installation: Install new fuel hoses (19).

 Pliers for click clamps

*171589003700

44

Seal connections of the fuel hoses (19) and fuel lines (20) with suitable stop plugs.

 Record plug

*129589009100

45

Remove propeller shaft from transmission output flange.

Engine 654 in model 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR41.10-P-0050LWX

Engine 654 in model 205
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR41.10-P-0050LW

46

Detach diagonal struts (22) from longitudinal member and remove from front axle carrier.

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

 Bolt, front diagonal strut to front axle carrier/torsion bar bearing shell/radiator mounting console

*BA61.10-P-1006-01L

 Bolt, front diagonal strut to longitudinal member

*BA61.10-P-1007-01L

 Engine mount wrench set

*001589011600

47

Remove steering coupling from steering shaft.

AR46.10-P-8000LW

48

Remove front axle rpm sensors (L6/1, L6/2) from the steering knuckles.

AR42.30-P-0712LW

49

Unclip electric lines of the spring links and steering knuckles.

50

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

AR42.10-P-0070LW

51

Remove steering knuckles from top transverse control arms.

AR33.25-P-0400LW


Secure the steering knuckle again folding away.
Otherwise the joints will be damaged.

52

Detach suspension struts from spring links.

Model 205 with engine 654
with code 489 (AIRMATIC)
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Model 253 with engine 654
with code 489 (AIR BODY CONTROL)
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR32.25-P-1017LWL

Model 205 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 489 (AIRMATIC)
Model 253 with engine 654
with code M005 (Vehicles with 4MATIC/all-wheel drive)
except code 489 (AIR BODY CONTROL)

AR32.25-P-1017LW

53

Support front axle carrier with lifting platform.



000 588 03 62 00 Lifting platform

WS01.00-P-0091A

54

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

55

Remove rear engine carrier from frame floor assembly.

AR22.10-P-1160LWB

 The rear engine support remains on the transmission.

56

Remove screws of the front axle carrier from the longitudinal member.

 Bolt, front axle carrier to longitudinal member

*BA33.10-P-1001-01Q

57

Lower engine transmission unit until the high-voltage plug on the transmission is accessible.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))


Carefully lower engine transmission unit with front axle carrier and radiator package When lowering, do not subject any lines and hoses to tension.
Otherwise damage will occur.

 Lifting platform

*000588036200

58

Release and disconnect high-voltage plug of the electric machine, place the cable duct of the high-voltage lines to one side, and seal connections with suitable protective covers.

Engine 654 in model 253.311/911
with code M005 (Vehicles with 4MATIC/all-wheel drive)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))


Cover high-voltage plug and handle carefully.
Otherwise the high voltage on-board electrical system may be damaged.

 Bolt, hoop guard to transmission

*BA08.10-P-1002-01F

 Bolt, 3-phase high-voltage line to electrical machine housing

*BA08.10-P-1003-01F

 Set of protective caps

*001589029100

59

Lower engine transmission unit with front axle carrier and radiator package.


Carefully lower engine transmission unit with front axle carrier and radiator package When lowering, do not subject any lines or hoses to tension or crush or kink them.
Otherwise damage will occur.

 Aid of helper required.

 Lifting platform

*000588036200

60

Fasten steering knuckles with a tensioning strap to the engine.

61

Install in the reverse order.

Concluding tasks

62

Check engine oil level and correct if necessary.



AP18.00-P-1812MKI

 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

 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

63

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

64

Perform chassis alignment.

AR40.20-P-0200LW

65

Connect vehicle diagnosis system, read out fault memory and clear if necessary.



AD00.00-P-2000-04B

66

Calibrate Distance Pilot DISTRONIC controller unit.

Engine 654 in model 205, 253
with code 233 (Adaptive cruise control Plus (DISTRONIC PLUS))
with code M005 (Vehicles with 4MATIC/all-wheel drive)
Engine 654 in model 205, 253
with code 239 (Adaptive cruise control Pro (DISTRONIC PRO))
with code M005 (Vehicles with 4MATIC/all-wheel drive)



AD00.00-P-2000-04B

67

Install lower engine compartment lining.

AR61.20-P-1105LW

 Ground points

Number

Designation

Model 253 (except 253.99)

BA00.19-P-1043-01E

Nut, ground line to pin/underfloor

M8

Nm

20

 Electric motor

Number

Designation

Model 253 (except 253.992/993)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.10-P-1002-01F

Bolt, hoop guard to transmission

Nm

15

 Electric motor

Number

Designation

Model 253 (except 253.992/993)
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in))

BA08.10-P-1003-01F

Bolt, 3-phase high-voltage line to electrical machine housing

Nm

12

 Front axle carrier

Number

Designation

Model 205

Model 253

BA33.10-P-1001-01Q

Bolt, front axle carrier to longitudinal member

Nm

180

180

 Wiring harness

Number

Designation

Model 205

Model 253

BA54.18-P-1001-02C

Nut, positive line to busbar on firewall

M6

Nm

8

8

M8

Nm

16

16

 Frame floor assembly

Number

Designation

Model 205

Model 253

BA61.10-P-1006-01L

Bolt, front diagonal strut to front axle carrier/torsion bar bearing shell/radiator mounting console

Nm

50

50

 Frame floor assembly

Number

Designation

Model 205

Model 253

BA61.10-P-1007-01L

Bolt, front diagonal strut to longitudinal member

Nm

50

50

 Cross member and front reinforcement

Number

Designation

Model 205

BA62.30-P-1003-01H

Bolt, strut to cross member

M8

Nm

20

 Cross member and front reinforcement

Number

Designation

Model 205

Model 253

BA62.30-P-1004-01H

Bolt, strut to soundproofing

M8

Nm

20

20

 Cross member and front reinforcement

Number

Designation

Model 205

Model 253

BA62.30-P-1007-01H

Screw, front module carrier/cross strut to body/angle bracket for front module carrier

Nm

11

11

 Cross member and front reinforcement

Number

Designation

Model 205

Model 253

BA62.30-P-1008-01H

Bolt, lock striker to cross member/front-module carrier

Nm

10

10

 Air conditioning

Number

Designation

Model 205

Model 253

BA83.30-P-1002-01Q

Nut, line to condenser

Nm

12

12

 Air conditioning

Number

Designation

Model 205

Model 253

BA83.30-P-1004-01Q

Nut, refrigerant line to connecting point

Nm

12

12