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

ENGINE 275 in MODEL 215, 220 with CODE (487) Active Body Control (ABC) 

Shown on model 220 

Fig 1: Identifying Engine Remove/Install Components (Shown On Model 220)

Fig 2: Identifying Engine Remove/Install Components (1 Of 2)

Fig 3: Identifying Engine Remove/Install Components (2 Of 2)

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	Risk of injury  to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning  caused by swallowing hydraulic fluid.	Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.	AS00.00-Z-0013-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
1	Remove transmission		AR27.10-P-0500I
2	Drain coolant from radiator		AR20.00-P-1142H
3	Drain coolant for low temperature circuit		AR20.00-P-1142HM
4	Evacuate engine oil, drain
	Engine oil and filter change		AP18.00-P-0101H
5	Remove left air filter housing (1)		AR09.10-P-1150LA
6	Remove poly-V-belt		AR13.22-P-1202L
7	Remove vacuum line (2) to purge control valve
8	Remove coolant expansion reservoir (3) for coolant
9	Disconnect coolant hose (4) at alternator (G2)	Inspect condition of coolant hose and hose clamp, replace if necessary.
10	Remove coolant hose (5) from thermostat to radiator and additional radiator	Check condition of coolant hose, O-ring, clamp and hose clamps, replace if required.
11	Disconnect both coolant hoses (6) of low temperature circuit from radiator pipe	Check condition of coolant hoses and hose clamps, replace if required.
12	Remove coolant hose (7) from coolant pump to radiator, expansion reservoir (3) and additional radiator	Check condition of coolant hose, O-ring, clamp and hose clamp, replace if required.
13	Disconnect line to additional radiator
14	Disconnect heater hose (8)	Check condition of heater hose and clamp, replace if required.
15	Suction off hydraulic fluid from oil reservoir (9) of power steering pump	The oil reservoir of the power steering pump and ABC oil reservoir form one unit and cannot be separated.
		Hand pump	Figure
16	Suction off hydraulic fluid out of ABC oil reservoir (9)	Hand pump	Figure
17	Unplug plug (10) of power steering pump throttle valve
18	Dismount ground cable (11) of power steering pump at body
19	Disconnect feed line (12) of power steering pump at oil reservoir (9) of power steering pump	Seal the connections.
		Check condition of hose clamp and feed line (12) and replace if necessary.
		Set of plugs	Figure
20	Disconnect feed line (13) of Active Body Control at oil reservoir (9) of Active Body Control	Seal the connections.
		Check condition of hose clamp and feed line (13) and replace if necessary.
		Set of plugs	Figure
21	Disconnect return line (14) of power steering pump at oil reservoir (9) of power steering pump	Seal the connections.
		Check condition of hose clamp and return line (14) and replace if necessary.
		Set of plugs	Figure
22	Disconnect ABC return line (15) from ABC oil reservoir (9)	Seal the connections.
		Check condition of hose clamp and return line (15) and replace if necessary.
		Set of plugs	Figure
23	Disconnect electrical connector (16) from brake system hydraulic unit
24	Unscrew nuts (19) and remove oil reservoir (9)
25	Dismount hydraulic line (17) of power steering at power steering pump	Seal the connections.
		Installation:  Install new O-ring.
		Set of plugs	Figure
			*BA46.30-P-1003-01C
26	Unscrew banjo bolt (18) of pressure line for Active Body Control at power steering pump	Seal connections.
		Installation:  Install new O-ring.
		Set of plugs	Figure
			*BA46.30-P-1012-01C
27	Unscrew bolts (20) of oil cooler line (21) at crankcase	Installation: Install new O-ring.
			*BA18.30-P-1004-01B
28	Separate electrical connector (A9x1) of refrigerant compressor (A9)
29	Unscrew bolts (22) for refrigerant compressor (A9)	Place refrigerant compressor (A9) with connected lines to the side in engine compartment.
			*BA83.55-P-1001-01A
30	Disconnect hydraulic line (17) of power steering at hydraulic hose (23) and dismount from crankcase	Hydraulic line remains in engine compartment.
			*BA46.30-P-1017-01C
31	Unscrew banjo bolt (24) of Active Body Control hydraulic line at valve unit of pressure supply	Seal the connections.
		Installation:  Install new O-ring.
		Set of plugs	Figure
			*BA32.50-P-1017-01A
32	Dismount right oil cooler line (25) at oil cooler	Seal the connections.
		Set of plugs	Figure
			*BA18.30-P-1003-01B
33	Disconnect transmission oil line (26) at radiator	Seal the connections.
		Set of plugs	Figure
			*BA20.20-P-1001-01A
34	Disconnect engine wiring harness		AR15.18-P-1000-02MC
35	Dismount vacuum line (27) of brake booster at rear intake manifold
	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
36	Disconnect fuel hose (28) at fuel line	Release fuel pressure through service valve.
		Pressure hose	Figure
			*BA07.52-P-1002-01E
37	Mount rear lifting eye onto engine	Lifting eye	Fig 7
38	Attach engine hoist to engine lifting eyes	Engine hoist	*WE58.40-Z-1012-11A
39	Unscrew bolts (29) of front engine mounts at front axle carrier		*BA22.10-P-1001-01L
40	Lift out engine	Ensure, when lifting out engine that no cables and lines are damaged and that engine does not lean against firewall.
		Engine hoist	*WE58.40-Z-1012-11A
41	Install in the reverse order
42	Fill and bleed active body control (ABC)		AR32.50-P-0021N
43	Fill power steering pump and bleed		AR46.30-P-0010N
44	Inspect 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 a running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
45	Check for leaks with engine running
46	Read out fault memory with STAR DIAGNOSIS and erase if necessary.	STAR DIAGNOSIS diagnosis system	*WH58.30-Z-1048-13A

FUEL DISTRIBUTOR

OIL COOLING SYSTEM

RADIATOR, COOLANT HOSES

ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE MOUNTS, ENGINE SUPPORTS

ACTIVE BODY CONTROL SUSPENSION

POWER STEERING PUMP

REFRIGERANT COMPRESSOR

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)

Fig 5: Identifying Pressure Hose (119 589 04 63 00)

Fig 6: Identifying Hand Pump (210 589 00 71 00)

Fig 7: Identifying Lifting Eye (285 589 01 61 00)