Remove/install engine - AR01.10-P-2400GZ (ML500)

WARNING: This page does not describe the selected car, but rather 28 other vehicles, including the 2012 Mercedes-Benz GL550, 2012 Mercedes-Benz GL450, 2011 Mercedes-Benz ML63, 2011 Mercedes-Benz ML550, and 2011 Mercedes-Benz ML350. However, it is still accessible from the selected car via links, so may be relevant.

ENGINES 113.964 in MODEL 164.175

Fig 1: Identifying Engine Remove/Install Components - Engines 113.964

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on vehicle with offroad package, code 430

Fig 2: Identifying Engine Remove/Install Components (Shown On Vehicle With Offroad Package, Code 430)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine Remove/Install Components - Engines 113.964 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Engine Remove/Install Components - Engines 113.964 (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

25.6.07	Steps adapted to changed repair method
	Observe tightening procedure when assembling propeller shaft, added	Operation step 24, 36

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of 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
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	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	Move DIRECT SELECT gear selector switch to position "N"
2	Release parking brake
3	Disconnect battery ground cable	Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery. Vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until ignition is switched off. Remove the Keyless Go transmitter card or transmitter key from vehicle and store beyond reach of the transmitter (at least 2 m).	AR54.10-P-0003GZ
	Notes on battery		AH54.10-P-0001-01A
4	Remove engine trim panel		AR01.10-P-2405GZ
	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. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
5	Remove fuel hose (1) from fuel distributor	Release fuel pressure with pressure hose via service valve	AR07.03-P-1460-01GZ
			*BA07.52-P-1001-01A
			Fig 6
6	Suction off hydraulic fluid from the expansion reservoir of power steering (7)		Fig 7
7	Drain coolant at radiator		AR20.00-P-1142GZ
	Notes on coolant		AH20.00-N-2080-01A
8	Detach coolant hose at thermostat housing connection fitting (2)	Check condition of coolant hose and hose clamps, replace if required.
9	Remove coolant hoses at top coolant pump connection fitting (3) and bottom coolant pump connection fitting (4)	Check condition of coolant hoses and hose clamps, replace if required.
10	Remove fan shroud with fan		AR20.40-P-5000GZ
11	Attach guard plate for radiator/condenser
	Guard plate for radiator/condenser		WF58.50-P-0110-01A
12	Remove poly-V belt		AR13.22-P-1202GZ
13	Remove banjo bolt (5) power steering line at power steering pump	Seal the connections.	AR46.25-P-3015RT
			Fig 5
14	Detach vacuum line for brake booster (6) at hot film mass air flow sensor	In doing so, push outer face to the rear and pull out vacuum line.
15	Remove coolant hose (8) of heat exchanger from connection to firewall (9)	Check condition of coolant hose (8) and hose clamp; replace if necessary.
16	Disconnect electrical plug connector (10) at purge switchover valve (Y58/1)
17	Remove purge line (12) from purge control valve (Y58/1)
18	Remove purge switchover valve (Y58/1) from rubber support	Put down purge control valve (Y58/1) with remaining connected line on the engine.
19	Disconnect engine wiring harness		AR01.00-P-2410GZ
20	Secure vehicle on the lifting platform		AR00.60-P-0100GZ
21	Remove bottom engine compartment paneling		AR61.20-P-1105GZ
22	Remove refrigerant compressor	Attach refrigerant compressor to bottom of engine compartment with lines connected.	AR83.55-P-5300GZ
23	Remove complete exhaust system	On vehicles with engine damage it is necessary to inspect the exhaust system for metal debris before installing it and to remove any metal debris present, otherwise damage to the catalytic converter system may occur.	AR49.10-P-7000GZ
24	Detach rear axle transmission propeller shaft (14) from transfer case (15)	Mark rear propeller shaft (14) relative to propeller shaft flange.
		Installation: Observe tightening procedure for rear propeller shaft (14) to transfer case (15).	AR41.10-P-0050-17GZ
			Fig 9
			*BA41.10-P-1001-01F
25	Remove heat protection	Only on vehicles with offroad package code 430.
26	Disconnect electrical connectors (16a) at transfer case (15)	Only on vehicles with offroad package code 430. Three connectors.
27	Disconnect ISM connector (16b) at intelligent servo module for DIRECT SELECT(A80)
28	Remove bolts (17) and remove exhaust bracket (18)	Only necessary on the right side of the transmission (25).
			*BA49.10-P-1001-01S
29	Remove shield (19) and detach transmission control electrical connector (20) from electric controller unit		AR27.40-P-0700-01GZ
			*BA27.40-P-1003-01E
30	Remove cover (21) and detach torque converter (35) from drive plate (36)	Do not use an impact wrench or compressed-air tool, otherwise the threads in the torque converter (35) will be damaged.	AR27.20-P-0100-01GZ
			*BA27.20-P-1002-01C
31	Remove bolt (22) at oil pan oil cooler line bracket (23)		*BA27.55-P-1003-01D
32	Remove bolt (26) for double hose clamp at alternator bracket (27)		*BA27.55-P-1004-01D
33	Detach oil cooler lines (24) from transmission (25) and engine oil pan and place to one side	Do not bend or kink oil cooler lines (24). Seal connections on transmission (25) and oil cooler lines (24) immediately using stop plugs. Installation: Replace O-rings.
			*BA27.55-P-1002-01D
			Fig 5
34	Support transmission (25) using transmission jack and transmission platform (01)	Lower the transmission (25) slightly and secure it on the transmission plate (01) with a tensioning strap to prevent it from falling down. Transmission platform, see GOTIS http://gotis.aftersales.daimlerchrysler.com Transmission jack, see GOTIS http://gotis.aftersales.daimlerchrysler.com
35	Remove bolts (28) and bolt (29), remove engine crossmember (30)	Installation: The bolts (29) must be replaced. Check rear engine mount for wear and replace if necessary.	AR22.10-P-1170GZA
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
36	Remove front propeller shaft (34)	Mark front propeller shaft (34) to the propeller shaft flanges. Installation: Observe tightening procedure for front propeller shaft (34). AR41.10-P-0070-03GZ
			Fig 9
			*BA41.10-P-1003-01F
			*BA41.10-P-1004-01F
37	Detach transmission (25) from cylinder crankcase and oil pan by removing the bolts (31) of the transmission bell housing	First unscrew the bolt on the vent line bracket (32) and remove the vent line (33). Secure starter to prevent it from falling out.
			*BA27.40-P-1001-01E
			*BA27.40-P-1002-01E
			*BA15.30-P-1003-01A
38	Remove transmission (25) from below	Secure torque converter (35) to prevent it from falling out. Installation: Align tapped holes of torque converter (35) to bore holes for drive plate (36).
39	Remove front bolts of engine mount to engine support (37)		*BA22.10-P-1002-03G
40	Attach engine hoist with adapter for engine hoist in engine lifting eyes	Engine hoist (self-locking) see GOTIS http://gotis.aftersales.daimlerchrysler.com
			Fig 8
41	Lift out engine	Set engine in an horizontal position in stages with engine hoist and run out to the front with engine hoist.
42	Install in the reverse order
43	Fill power steering pump and bleed		AR46.30-P-0010GZ
44	Fill cooling system		AR20.00-P-1142GZ
45	Inspecting cooling system for leaks	If cylinder head gaskets are new, warm up engine first of all to operating temperature otherwise complete filling of the engine with coolant is not assured.	AR20.00-P-1010GZ
46	Check engine oil level		AR18.00-P-3035-01GZ
			Fig 10
			*BF18.00-P-1001-03U
			*BF18.00-P-1002-03U
			*BF18.00-P-1003-03U
			*BF18.00-P-1004-03U
47	Check oil level in transmission (25) and correct if necessary		AR27.00-P-0100W
	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	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
48	Carry out engine test run and check engine for proper operation and leaktightness

FUEL DISTRIBUTOR

Number	Designation		Engine 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/988
BA07.52-P-1001-01A	Fuel feed line to fuel distributor	Nm	38

PROPELLER SHAFT

Number	Designation			Model 164.1/8
BA41.10-P-1001-01F	Self-locking screw, front propeller shaft to transfer case (rear axle side)	Stage 1	Nm	40
BA41.10-P-1001-01F		Stage 2	∠°	90
BA41.10-P-1003-01F	Self-locking bolt, propeller shaft to transfer case (to front axle)	Stage 1	Nm	40
BA41.10-P-1003-01F		Stage 2	∠°	90
BA41.10-P-1004-01F	Self-locking bolt, propeller shaft to front axle gear	Stage 1	Nm	40
BA41.10-P-1004-01F	Self-locking bolt, propeller shaft to front axle gear	Stage 2	∠°	90

TORQUE CONVERTER

Number	Designation				Transmission 722.9
BA27.20-P-1002-01C	Bolt, torque converter to drive plate	Straight threaded connection		Nm	42
		Helical cut	Stage 1	Nm	4
			Stage 2	Nm	30
			Stage 3	∠°	90

EXHAUST SYSTEM

Number	Designation		Engine 113.964 in model 164.1
BA49.10-P-1001-01S	Bolt, catalytic converter bracket to catalytic convertor	Nm	20

TRANSMISSION OIL COOLING SYSTEM

Number	Designation				Transmission 722.9
BA27.55-P-1002-01D	Bolt, transmission oil line to transmission housing	Banjo bolt	Stage 1	Nm	5
		Banjo bolt	Stage 2	∠°	90
		Hexalobular bolt		Nm	12
BA27.55-P-1003-01D	Bolt, oil cooler line to engine oil pan			Nm	12
BA27.55-P-1004-01D	Bolt, dual clamp to oil line			Nm	8

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 164
BA22.10-P-1002-03G	Bolt connecting front engine mount to engine support	Nm	53

STARTER

Number	Designation		Engine 113.964 in model 164
BA15.30-P-1003-01A	Bolt connecting starter to crankcase	Nm	40

HOUSING

Number	Designation		Transmission 722.9 in model 164
BA27.40-P-1001-01E	Bolt, automatic transmission to crankcase	Nm	39
BA27.40-P-1002-01E	Bolt, automatic transmission to engine oil pan	Nm	39
BA27.40-P-1003-01E	Bolt, heat shield to transmission housing	Nm	8

OIL LEVEL CHECK

Number	Designation			Engine 113.964/971
BF18.00-P-1001-03U	Oil level	Maximum	mm	127
BF18.00-P-1001-03U	Oil level	Minimum	mm	101
BF18.00-P-1002-03U	Dipstick indication 88 mm to 124 mm (oil level too low)	88 mm	Replenish oil quantity in liters	+2.9
		90 mm	Replenish oil quantity in liters	+2.8
		92 mm	Replenish oil quantity in liters	+2.6
		94 mm	Replenish oil quantity in liters	+2.5
		96 mm	Replenish oil quantity in liters	+2.4
		98 mm	Replenish oil quantity in liters	+2.3
		100 mm	Replenish oil quantity in liters	+2.2
		102 mm	Replenish oil quantity in liters	+2.1
		104 mm	Replenish oil quantity in liters	+1.9
		106 mm	Replenish oil quantity in liters	+1.8
		108 mm	Replenish oil quantity in liters	+1.7
		110 mm	Replenish oil quantity in liters	+1.5
		112 mm	Replenish oil quantity in liters	+1.4
		114 mm	Replenish oil quantity in liters	+1.2
		116 mm	Replenish oil quantity in liters	+1.0
		118 mm	Replenish oil quantity in liters	+0.9
		120 mm	Replenish oil quantity in liters	+0.7
		122 mm	Replenish oil quantity in liters	+0.5
		124 mm	Replenish oil quantity in liters	+0.3
BF18.00-P-1003-03U	Oil dipstick indication 126 mm to 128 mm (oil level correct)	126 mm	Oil quantity in liters	0.0
		127 mm	Oil quantity in liters	0.0
		128 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03U	Oil dipstick indication 130 mm to 138 mm (oil level too high)	130 mm	Extract oil quantity in liters	-0.3
		132 mm	Extract oil quantity in liters	-0.5
		134 mm	Extract oil quantity in liters	-0.7
		136 mm	Extract oil quantity in liters	-0.9
		138 mm	Extract oil quantity in liters	-1, 1

Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Hand Pump (210 589 00 71 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Adapter For Engine Hoist (164 589 00 62 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Retainer Wrench (164 589 02 07 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Identifying Dipstick (120 589 07 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.