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

ENGINE 137.970 in MODEL 215.378, 220.178 /878 

Fig 1: Identifying Engine Remove/Install Components (1 Of 4)

Fig 2: Identifying Engine Remove/Install Components (2 Of 4)

Fig 3: Identifying Engine Remove/Install Components (3 Of 4)

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

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Secure vehicle on the lifting platform
2	Remove transmission		AR27.10-P-0500I
	Risk of injury  to skin and eyes due to scalding caused by contact with hot coolant spray Risk of poisoning  caused by 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
3	Drain coolant at radiator		AR20.00-P-1142HA
4	Drain engine oil or extract	When removing/installing the engine, the engine oil must be completely drained or suctioned off, otherwise there is danger that engine oil can enter into the intake manifold via the crankcase ventilation. This can result in engine damage: ↓
		Suction off engine oil	AP18.00-P-0101-02Z
	When refilling see: →
		Engine - oil and filter change	AP18.00-P-0101L
5	Remove fan shroud with suction fan (5)		AR20.40-P-6800AC
6	Remove air filter housing (1).		AR09.10-P-1050L
7	Remove hot film mass air flow sensor		AR07.07-P-1453L
8	Remove vacuum line, for this step dismount vacuum line (2) at purge control valve (Y58/1) and at intake connection
9	Detach pneumatic line (26) at intake connection
10	Unclip vacuum line (3) of brake booster at intake connection
11	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
12	Remove coolant line on thermostat housing (7) and on radiator (8); disconnect coupling (arrow) and remove
13	Detach coolant line to coolant expansion reservoir (10) on thermostat housing (7)
14	Dismount coolant line (11) at connection (12) of heat exchanger
15	Dismount coolant line at generator
16	Remove coolant line (9) at bottom on coolant pump
17	Remove transmission oil line (13); remove transmission oil line (13) on radiator (8) and disconnect at separation point (arrow)	Seal the connections.
		Installation:  Check oil level in automatic transmission; correct if necessary.	AR27.00-P-0100AC
			*BA20.20-P-1001-01A
18	Dismount transmission oil line (14) at radiator (8)	Seal the connections.
		Installation:  Check oil level in automatic transmission; correct if necessary.	AR27.00-P-0100AC
			*BA20.20-P-1001-01A
19	Dismount engine oil line at radiator
20	Suction off oil from expansion reservoir (16) of power steering		Fig 5
		Installation:  Fill power steering pump and bleed:
		Model 215, 220 except 220.878	AR46.30-P-0010N
		Model 220.878	AR46.30-P-0010B
21.1	Remove expansion reservoir (16) for power steering together with expansion reservoir (17) for Active Body Control suspension and close of lines using a set of stop plugs	Model 215.378, 220.178
			Figure
21.2	Remove expansion reservoir (16) for power steering and close off lines using a set of stop plugs	Model 220.878
			Figure
	Risk of explosion  caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.	AS83.00-Z-0001-01A
22	Drain air conditioning (recycle)	Replenish extracted quantity of compressor oil in the refrigerant circuit (fresh oil) when filling the air conditioning system. Installation:  Evacuate air conditioning system, refill and check for leaktightness.
	Procedure for a damaged or leaky air conditioning system		AH83.30-N-0004-01A
	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
	Notes on handling refrigerant R134a		AH83.30-N-0003-01A
23	Dismount suction and pressure oil lines at power steering pump (15)	Seal the connections.
			*BA46.30-P-1003-01C
24	Dismount refrigerant lines at condenser and at separation point of left strut tower	Installation:  →
		Replace fluid reservoir of air conditioning system.	AR83.30-P-6520M
			*BA83.55-P-1002-01A
25	Remove front exhaust system (21)		AR49.10-P-5531L
	Risk of explosion  caused by fuel igniting, risk of poisoning  caused by inhaling and swallowing fuel and risk of injury  to eyes and skin caused by contact with fuel	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
26	Dismount fuel feed line (4) to coupling (arrow)	Before removing, open fuel tank cap and drain the system pressure at the service valve on the fuel distributor.
			*BA07.52-P-1001-01A
27	Attach engine hoist to engine lifting eyes
28	Detach hydraulic line (18) for Active Body Control suspension on valve unit for pressure supply to the Active Body Control (19)	Seal the connections.
29	Remove bolts for pressure oil line for power steering on oil pan at the rear
30	Dismount engine wiring harness		AR01.00-P-2410LA
31	Unscrew bolts (25) of front engine mount to front axle carrier		AR22.10-P-1260L
			*BA22.10-P-1001-01L
32	Lift out engine	Ensure, when lifting out engine that no cables and lines are damaged and that engine does not lean against firewall.
33	Install in the reverse order
34	Inspecting cooling system for leaks	If new cylinder head gaskets fitted: Bring engine to normal operating temperature, then check cooling system for leaks.	AR20.00-P-1010HA
	Risk of accident  due to vehicle starting off when engine is running Risk of injury  caused by contusions and burns during starting procedure or when working near the engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
35	Conduct engine test run and check engine for leaks whilst it is running	In the event of oil loss determine and eliminate cause, otherwise malfunctions, transmission damage, and serious environmental pollution may occur.
36	Read out fault memory and erase	When the work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. →
		Connect STAR DIAGNOSIS and read out fault memory	AD00.00-P-2000-04A

FUEL DISTRIBUTOR

RADIATOR, COOLANT HOSES

ENGINE MOUNTS, ENGINE SUPPORTS

POWER STEERING PUMP

REFRIGERANT COMPRESSOR

Fig 5: Identifying Hand Pump (112 589 00 72 00)

Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)