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Home >> Mercedes Benz >> 1996 >> E320 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Complete Engine - Testing & Repair - 210 Chassis - 1 Of 2 >> Testing & Repair >> Remove/install engine - AR01.10-P-2400HA

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

ENGINE 604, 605 in MODEL 202 

ENGINE 604, 605, 606.912 in MODEL 210 

Fig 1: Identifying Engine Components (1 Of 2)
G04634515Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Engine Components (2 Of 2)
G04634516Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install     
1 Disconnect ground cable from battery   AR54.10-P-0003A
2 Remove bottom section of sound-proofing capsule Model 202 AR94.30-P-5300A
    Model 210 AR94.30-P-5300AB
3 Remove charge air pipes on left and right to charge air cooler Model 202 with engine 605.960
Model 210 with engine 605.962		 AR09.41-P-1311H
DANGER Risk of injury  to skin and eyes caused by scalding from contact with hot coolant spray. 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
4 Drain coolant from radiator   AR20.00-P-1142HW
5.1 Remove radiator Model 202
Model 210 with engine 606.912		 AR20.20-P-3865HA
6.1 Remove poly-V belt (8) if AC (code 580, 581) fitted AR13.22-P-1202HA
7.1 Attach guard plate (10) for radiator / condenser if AC (code 580, 581) fitted  
REFER TO SHOP-MADE TOOLS Guard plate for radiator / condenser   WF58.50-P-0110-01A
8 Detach vacuum lines IMPORTANT At vacuum pump, intake manifold, brake booster.
If transmission 722.4 fitted: at vacuum control valve.
Vacuum units of exhaust gas recirculation. On turbocharged engine: Vacuum line at the vacuum control unit turbocharger
IMPORTANTInstallation:  for vacuum line routing, see ↓		  
    Engine 604.910 with manual or automatic transmission with TWC AD07.13-P-2001-06A
    Engine 604.912 with manual or automatic transmission with TWC AD07.13-P-2001-06B
    Engine 605.910 AD07.12-P-2000-05C
    Engine 605.912 with manual transmission with TWC AD07.12-P-2000-05D
    Engine 605.912 with manual of automatic transmission, Engine 605.960 AD07.12-P-2000-05A
    Engine 606.961 AD07.12-P-2000-05B
9 Detach coolant hoses (12, 36) at cylinder head and at coolant thermostat housing IMPORTANT Model 210 with engine 606: detach coolant hose (36) after positioning engine at an angle. Inspect condition of hose clips and hoses, replace if necessary.  
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1002-06A 
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1001-06A 
10 Unbolt lines (28, 29) of power steering pump Before disconnecting the lines, extract oil at reservoir.
IMPORTANTInstallation:  With level control (Code 217B) ↓		 AR46.30-P-0500A
    Emptying and filling pressure oil system AR32.30-P-0630A
11.1 Detach control pressure Bowden cable (15) of automatic transmission If automatic transmission 722.4 fitted
IMPORTANTInstallation:  ↓		  
    Inspect setting of control pressure Bowden cable (15), adjust to correct setting AR30.10-P-1010HB
12 Disconnect engine wiring harness (21) Model 202 AR01.00-P-2410HA
    Model 210 up to 05.96 AR01.00-P-2410D 
    Model 210 as of 06.96 AR01.00-P-2410H 
DANGER 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
13 Disconnect fuel lines (90/1, 90/2) IMPORTANT Open fuel filler cap.  
14 Unbolt exhaust system at turbocharger or exhaust manifold and transmission intermediate bearing Model 202 AR49.10-P-7000I
    Engine 604.912, 605.912, 606.912 in model 210.0 AR49.10-P-7000B
    Engine 605.912, 606.912 in model 210.2 AR49.10-P-7000BA
15 Unhinge shift rods (34) at transmission Manual transmission AR26.10-P-0020A
    Automatic transmission ra27047220600x
16.1 Separate clutch line (35) at transmission If manual transmission fitted AR25.20-P-0150A
17.1 Slacken clamping nut (41) of propeller shaft If clamping nut fitted to propeller shaft AR41.10-P-0050EA
18 Unbolt front propeller shaft at transmission, push to the rear   AR41.10-P-0050EA
19.1 Unhinge parking shift lock (66) at transmission If automatic transmission 722.6 fitted
NOTESThe park lock interlock must only be removed in selector lever position "P". 
IMPORTANTInstallation:  ↓		  
    Adjust cable for parking shift lock AR27.60-P-0965B
20.1 Remove guard plate (20) on right at transmission and separate plug connection (19) of electronic control unit at transmission If automatic transmission 722.6 fitted  
21.1 Unbolt AC compressor (37) If AC (code 580, 581) fitted:
Attach AC compressor at bottom in side of engine compartment with piping connected.		 *BA83.55-P-1001-01A 
22 Bolts (39, 40) of engine mounts and engine support Model 202  
    TORQUE SPECIFICATION *BA22.10-P-1002-01D 
    TORQUE SPECIFICATION *BA22.10-P-1003-01D 
    TORQUE SPECIFICATION *BA22.10-P-1008-01D 
    Model 210  
    TORQUE SPECIFICATION *BA22.10-P-1001-01D 
    TORQUE SPECIFICATION *BA22.10-P-1002-01D 
    TORQUE SPECIFICATION *BA22.10-P-1003-01D 
24 Raise engine (38), remove NOTES Ensure that the injection line is not damaged when attaching to front engine lifting eyes AR01.10-P-7500-03HA 
    IMPORTANT Model 210 with engine 604, 605: remove with removal fixture ↓ *WH58.30-Z-1002-07A 
25   Remove engine with removal fixture AR01.10-P-2400-01A 
    COMMERCIALLY AVAILABLE TOOLS *WE58.40-Z-1012-11A 
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1003-07A 
    COMMERCIALLY AVAILABLE TOOLS *WH58.30-Z-1002-07A 
26 Install in the reverse order    
DANGER Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near engine Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.		 AS00.00-Z-0005-01A
27.1 Inspect ATF level in automatic transmission Transmission 722.4 AR27.00-P-0100A
    Transmission 722.6 AR27.00-P-0101A
28 Inspect oil level of power steering pump, adjust to correct level   AP46.00-P-4611BB
29 Inspect cooling system for leaks NOTES Engine with new cylinder head gasket:
Do not pressure-test cooling system until engine has reached operating temperature.		 AR20.00-P-1010HA
30 Read fault memory, erase. 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. AD00.00-P-1000AZ
TORQUE SPECIFICATION Refrigerant compressor

Number Designation Engines 104.945/995, 111.942/947/970, 604.912/917, 605.912/962, 606.912/962 in model 210
BA83.55-P-1001-01A Bolt connecting refrigerant compressor to bracket Nm 23
TORQUE SPECIFICATION Engine suspension, engine mounts, engine supports

Number Designation Engine 604, 605 in model 202 Engine 604, 605, 606 in model 210
BA22.10-P-1001-01D Bolt connecting front engine mounts to front axle carrier Nm - 35
BA22.10-P-1002-01D Bolt connecting rear engine mount to rear engine crossmember Nm 25 30
BA22.10-P-1003-01D Bolt/nut, rear engine crossmember to body Nm 40 40
BA22.10-P-1008-01D Bolt connecting rear engine mount on frame crossmember Nm 25 -
Commercially available tools

Number Designation
WH58.30-Z-1001-06A 6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A 7 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1001-07A Shackle, DIN 82101
WH58.30-Z-1002-07A Engine carrier arm
WH58.30-Z-1003-07A Hook mount
Workshop equipment

WE58.40-Z-1012-11A Load regulator (engine hoist), self-locking
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