Remove/install engine - AR01.10-P-2400AP

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ENGINE 120.980 in MODEL 140

Fig 1: Identifying Engine Remove/Install Components (1 Of 5)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Engine Remove/Install Components (2 Of 5)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine Remove/Install Components (3 Of 5)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Engine Remove/Install Components (4 Of 5)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Engine Remove/Install Components (5 Of 5)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
1	Move engine hood to upright position
2	Disconnect ground cable of battery		AR54.10-P-0003A
3	Remove air filter with mass air flow sensor		AR09.10-P-1050F
4	Remove lower engine compartment paneling
5	Remove radiator		ra20001204200x
6	Unscrew left oil line for automatic transmission
7	Remove guard plate for condenser of air conditioning
8	Unclip left Bowden cable (engine hood lock)
9	Dismount rear coolant line at cylinder head
10	Remove viscous fan clutch with fan		AR20.40-P-5660AO
11	Dismount poly-V-belt		AR13.22-P-1202AO
	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	Close fuel lines (60) and dismount		Fig 6
		When loosening the fuel lines, counterhold the connection fittings.
13	Remove the cable mount cover (6)
14	Disconnect electrical connectors (engine wiring harness)	At ignition control units (N1/4, N1/5) Crankshaft angle position sensor connector (L5/4, L5/5) Knock sensor connector (A16g1, A16g2) Diagnostic socket (X11/2, X11/3) TDC sensor connector at diagnostic sockets (X11/2, X11/3) Ignition cable 4 at high-voltage distributor (S5/5, S5/6) Disconnect in cable mount (6) and remove Left camshaft position sensor (X47/3) Right camshaft position sensor (X47/4) At control unit box connector for engine separation point (X26/17) Left crankshaft position sensor (L5/4) Right crankshaft position sensor(L5/5) Knock sensor lines (A16g1 and A16g2)
15	Disconnect vacuum lines in cable mount and pull out of cable mount.	Unclip cable mount cover and dismount 2-way valve Automatic transmission Ignition control units
16	Remove the cable mount (6)
17	Pull out air pump connector at right wheelhouse	During air injection
18	Remove Bowden cable (regulator) (98)	Installation: Adjust Bowden cable regulator	AR30.10-P-1010F
19	Unscrew brake booster vacuum lines at intake manifold
20	Power steering pump, draw off oil from the reservoirs	Installation: Fill power steering pump and bleed.	ra46097650715x
21	Dismount oil lines for power steering pump (26, 27, 28, 29)
22	Unscrew bracket for engine oil cooler line (arrow)
23	Unscrew engine oil cooler lines (13 and 14) at air oil cooler and right engine oil cooler line (13) at radiator crossmember
24	Remove oil pressure switch (B5)	to facilitate removal of the AC compressor from engine with pipe system connected.
25	Detach AC compressor (11) with pipe system connected	For this step unscrew bolts (1).
26	Remove exhaust system (7) complete		AR49.10-P-7000F
27	Drain coolant at crankcase		ra20001200100x
28	Unscrew shield (32) for starter wiring harness
29	Dismount connectors for starter wiring harness, disconnect line 30
30	Detach flexible coupling (arrows) at front propeller shaft		AR41.10-P-0050DA
31	Remove support for exhaust bracket at transmission		AR49.10-P-7000F
32	Unscrew ground cable from transmission
33	Remove rear engine support (10) without engine mount		AR22.10-P-1160AO
34	Detach shift rod (9) from transmission
35	Disconnect electrical connectors at the transmission
36	Unscrew front engine mount (12) at left and right at the front axle carrier		ra22001202110x
37	Attach engine hoist to lifting eyes		*WE58.40-Z-1012-11A
			*WH58.30-Z-1003-07A
38	Lift engine with transmission until the AC compressor (11) can be detached from the bracket at the engine with the pipe system connected.	Secure the AC compressor to one side in the engine compartment.
39	Lift engine further with engine hoist, remove	The removed engine must not be lowered onto the oil pan bottom section . Installation: Check front and rear engine mounts. Check and adjust engine Correct engine and transmission oil levels. Pour in coolant Inspect for leaks. Calibrate starter according to engine or crankcase replacement.	AR03.30-P-4350AO
		If the engine is replaced, use the improved versions of the coolant and heater hoses. These hoses are identified with "6254.12"
40	Install in the reverse order
41	Read out fault memory	Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Diagnosis Manual Volume 2: Index 0: Connecting and using test equipment.

Fig 6: Identifying Clamping Device (000 589 40 37 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1003-07A	Hook mount

WORKSHOP EQUIPMENT

WE58.40-Z-1012-11A

Load regulator (engine hoist), self-locking