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

ENGINE 271.940 in MODEL 203.042 /242 /742, 209.342 /442 with TRANSMISSION 716.6 

ENGINE 271.946 in MODELS 203.046 /246 /746 with TRANSMISSION 716.6 

ENGINE 271.948 in MODELS 203.040 /740 with TRANSMISSION 716.6 

ENGINE 271.921 in MODEL 203.730 with TRANSMISSION 716.6 

ENGINE 271.955 in MODELS 209.341 /441 with TRANSMISSION 716.6 

Shown on engine 271.940 

Fig 1: Identifying Engine Remove/Install Components - Shown On Engine 271.940 (1 Of 3)

Fig 2: Identifying Engine Remove/Install Components - Shown On Engine 271.940 (2 Of 3)

Fig 3: Identifying Engine Remove/Install Components - Shown On Engine 271.940 (3 Of 3)

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
	Notes on avoiding damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Open engine hood	Model 203	AR88.40-P-1000P
		Model 209	AR88.40-P-1000Q
	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 leadacid 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
2	Disconnect ground line from battery	Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
	Notes on battery		AH54.10-P-0001-01A
3	Take off top engine trim panels	Installation:  Moisten retaining rubber of engine covers with antifriction agent.
4	Remove suction pipe from air filter	Remove radiator crossmember
5	Remove electric fan		AR20.40-P-5000PR
6	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
7	Remove engine compartment paneling		AR61.20-P-1105P
	Risk of injury  to skin and eyes caused by scalding from 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
8	Drain coolant from radiator		AR20.00-P-1142PR
	Notes on coolant		AH20.00-N-2080-01A
9	Drain and collect engine oil	Installation:  Replace sealing ring of oil drain screw.
			*BA01.45-P-1007-01H
			*BF18.00-P-1001-01L
10	Remove coolant line between thermostat and radiator	Installation:  Replace sealing rings.
11	Remove coolant line (8) between engine, coolant circulation pump (M13) and engine radiator	Installation:  Install new sealing rings.
12	Slacken poly-V belt	Make use of Torx recess below tensioning pulley for this step and swivel in an anticlockwise direction.
		See Remove/install poly-V belt.	AR13.22-P-1202QK
13	Remove vacuum line from intake manifold
14	Remove pressure line (1) from intake manifold	Installation:  Replace sealing ring.
15	Slacken ground strap of refrigerant compressor (2)
16	Disconnect electrical connector for refrigerant compressor
17	Release fuel pressure through service valve		AR07.03-P-1460-01V
	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
18	Disconnect fuel line (7) at fuel distributor	Make sure to collect fuel.
		Pressure hose	Figure
			*BA07.52-P-1002-01B
19	Disconnect electrical connector (4)
20	Disconnect electrical connector (5) at ME control unit	Pull sliding lock and remove electrical connector (5) at ME control unit, unclip cable set off firewall (3) and place to the side.
21	Release vacuum fitting (6)	Press together connector to brake booster and to vacuum control and pull toward top.
22	Unclip radiator coolant line off firewall (3)
23	Remove battery positive cable	Slacken battery positive cable at battery terminal (14) and main fuse (13). Unclip cable set from firewall and fasten to engine.
24	Suction off oil from expansion reservoir of power steering	Hand pump	Figure
25	Slacken return line (10) of power steering.	Seal connections, in order to avoid foreign bodies getting in! Inspect condition of hose clamp and return flow line (10), replace if necessary.
		Set of stop plugs	Figure
26	Disconnect pressure line (11) at power steering pump	Seal connections, in order to avoid foreign bodies getting in! Installation:  Replace O-ring of pressure line (11).
		Set of stop plugs	Figure
			*BA46.30-P-1002-01E
27	Disconnect coolant line (12)
28	Remove exhaust system from primary catalytic converter		AR49.10-P-7000QK
29	Remove bracket (21)
30	Slacken refrigerant line (22) from transmission
31	Detach refrigerant compressor from engine and place to one side with connected lines		*BA83.55-P-1001-01G
	Risk of poisoning  caused by swallowing brake fluid. Risk of injury  caused by brake fluid coming into contact with skin and eyes.	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
32	Separate line connection for clutch control	Seal lines.
		Set of stop plugs	Figure
33	Unscrew bolts (18) of propeller shaft (23) at transmission	Mark position of propeller shaft (23) and flex disk.
		Push propeller shaft (23) downstream
			*BA41.10-P-1001-01A
34	Disconnect ground cable (20) from body
35	Unhook selector cable (19)
36	Detach gearshift linkage from transmission	Separate shift rod (24) by means of open end wrench from ball head The aluminum bridge (27) is being secured with a pin (26), which is retained with a sheet metal clamp to the right
37	Uncouple gearshift linkage	Shift rod (24) and aluminum bridge (27) must be fastened with a tie strap at clutch cable. This facilitates later installation.
38	Disconnect electrical connector (17) from reverse gear switch
39	Slacken downstream engine mount from engine crossmember.	Unscrew bolts (15).
			*BA22.10-P-1001-01O
			*BA22.10-P-1004-03B
40	Release engine crossmember from body	Only remove four outer bolts (16) of engine crossmember, slacken two middle bolts (16) by 1/4 revolution.
			*BA22.10-P-1003-01O
			*BA22.10-P-1005-03B
41	Unscrew bolts on front engine mount at front axle carrier		*BA22.10-P-1006-01O
			*BA22.10-P-1002-03B
42	Attach engine hoist to engine lifting eyes
		Model 203	Fig 7
		Load regulator, see GOTIS http://gotis.aftersales.daimlerchrysler.com
43	Support transmission with car jack.
44	Dismount engine crossmember from body	Unscrew the remaining two bolts at engine crossmember (16).
			*BA22.10-P-1003-01O
45	Lower engine towards the rear and lift out	Lower support (car jack) below transmission for this step. Tilt engine back in stages with engine hoist and run out to the front with engine trolley jack.
46	Install in the reverse order
47	Bleed clutch operating system		AR25.20-P-0070P
48	Inspect cooling system for leaks	Bring engine with new cylinder head gaskets first of all to operating temperature, otherwise it is not assured that the engine is fully filled with coolant.	AR20.00-P-1010P
49	Check engine oil level
	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 the engine as it is running Check for leaks with engine 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
51	Perform basic programming	Model 203	AR00.19-P-0200P
		Model 209	AR00.19-P-0200Q
52	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. The stored faults can be caused by removed cables, assembly operations, test operations as well as by a simulation.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

OIL PAN

FUEL DISTRIBUTOR

ENGINE SUSPENSION, ENGINE MOUNTS, ENGINE SUPPORTS

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

PROPELLER SHAFT

POWER STEERING PUMP

REFRIGERANT COMPRESSOR

CAPACITIES OF ENGINE LUBRICATION SYSTEM

Fig 4: Identifying Hand Pump (210 589 00 71 00)

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

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

Fig 7: Identifying Adapter (271 589 00 62 00)