Remove/install engine with front axle carrier - AR01.10-P-2500GZ (ML500)

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ENGINE 113.964 in MODEL 164.175

Fig 1: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 113.964

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on vehicle with offroad package, code 430

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

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 113.964 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 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 the propeller shaft, added	Step 26

	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 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
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates 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
	On vehicles with memory package (driver seat, steering column, mirrors) code 275 the easy entry/exit must be disabled otherwise damage can occur when reconnecting the battery, as the driver seat and steering wheel can move into another position, when for example the driver door is opened or closed. Disabling takes place via the buttons on the steering wheel in the "comfort" menu of the multifunction display
	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.	AR54.10-P-0003GZ
	Notes on battery		AH54.10-P-0001-01A
		Vehicles with Keyless Go code 889: Press the Keyless Go start and stop button repeatedly until the 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).
4	Secure vehicle on the lifting platform		AR00.60-P-0100GZ
5	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
6	Detach fuel line (1) from fuel distributor	Release fuel pressure with pressure hose via service valve	AR07.03-P-1460-01GZ
			*BA07.52-P-1002-01A
			Figure
7	Discharge air conditioning system	Vehicles with automatic air conditioning code 580 or comfort automatic air conditioning code 581.	AR83.30-P-1760GZ
8	Suction off hydraulic fluid from the expansion reservoir of power steering (7)		Figure
9	Drain coolant at radiator		AR20.00-P-1142GZ
	Notes on coolant		AH20.00-N-2080-01A
10	Detach coolant hose at thermostat housing connection fitting (2)	Check condition of coolant hose and hose clamps, replace if required.
11	Remove coolant hoses on upper coolant pump connection fitting (3) and lower coolant pump connection fitting (4)	Check condition of coolant hoses and hose clamps, replace if required.
12	Detach power steering lines at radiator connections (8)	Seal all connections immediately.
			Figure
13	Detach oil cooler lines at radiator connections (9)	Seal all connections immediately.
			Figure
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	Dismount coolant hose (10) for heat exchanger from connection to the firewall (11)	Check condition of coolant hose (10) and hose clamp; replace if necessary.
16	Remove refrigerant lines (5) on refrigerant compressor	Installation: Replace the gaskets.	AR83.55-P-5300GZ
17	Fix steering wheel in center position	Installation: On vehicles with memory package (driver seat, steering column, mirrors) code 275 the holding device must be removed before connecting the battery
			Fig 8
18	Disconnect steering shaft (16) on universal joint (17)	The bolt (18) must be completely unscrewed since it is fed into a groove.
			*BA46.10-P-1001-01J
19	Disconnect electrical plug connector (19) on purge switchover valve (Y58/1)
20	Disconnect purge line (19a) on purge control valve (Y58/1)
21	Remove purge switchover valve (Y58/1) from rubber support	Put down purge control valve (Y58/1) with remaining connected line on the engine.
22	Disconnect engine wiring harness		AR01.00-P-2410GZ
23	Remove wheels on the front axle
	Remove/install wheels		AP40.10-P-4050Z
24	Remove bottom engine compartment paneling		AR61.20-P-1105GZ
25	Remove 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
26	Detach rear propeller shaft (14) from transfer case (13)	Mark rear propeller shaft (14) relative to the propeller shaft flange (14a).
		Installation: Observe tightening procedure for rear propeller shaft (14) to transfer case (13).	AR41.10-P-0050-17GZ
			Figure
			*BA41.10-P-1001-01F
27	Remove heat shield (15)	Only on vehicles with offroad package code 430.
28	Disconnect electrical connectors (15a) at transfer case (13)	Only on vehicles with offroad package code 430. Three connectors.
29	Disconnect connectors of right front brake pad contact sensor and left front brake pad contact sensor at brake calipers (26)
30	Unscrew guide pins (20), remove brake calipers (26)	Fasten brake calipers with lines connected to upper transverse control arms (25). Installation: Replace guide bolts (20).
			*BA42.10-P-1002-10L
31	Remove bracket (21)	Installation: Install new tie straps.
32	Unscrew left front RPM sensor (L6/1) and right front RPM sensor (L6/2) from wheel carriers	Fasten all lines using a cable tie to suspension strut on corresponding side.
			*BA42.30-P-1001-01G
33	Unscrew nuts (23) on link rods of stabilizer bar (22)		*BA32.20-P-1004-02L
34	Unscrew nuts (24) on transverse control arms (25)		*BA33.20-P-1001-01J
			Fig 9
			Fig 10
35	Detach shock-absorber struts on lower transverse control arms		*BA32.25-P-1002-01G
36	Remove left and right underfloor paneling		AR61.30-P-1001GZ
37	Remove front wheelhouse lining	Remove both sides.	AR88.10-P-1300GZ
38	Position portable lifting platform with universal major assembly support at front axle carrier (33) and transmission oil pan	Support front axle and transmission. When doing so ensure that mounting plates are correctly aligned. Before removal the complete unit must be secured with the aid of a tensioning strap! Lifting platform (Master Gear) refer to GOTIS http://gotis.aftersales.daimlerchrysler.com Universal major assembly support refer to GOTIS http://gotis.aftersales.daimlerchrysler.com
39	Remove bolts (27) on engine crossmember (28)		AR22.10-P-1170GZA
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
40	Remove bolts (29) on front axle carrier (33) at front	Installation: Replace bolts (29).
			*BA33.10-P-1001-01I
41	Unscrew bolts M10 (30) and bolts M8 (31) on stiffening plates (32)	Installation: Replace bolts M10 (30) and bolts M8 (31).
			*BA33.10-P-1002-01I
			*BA33.10-P-1003-01I
42	Remove bolts (34) on front axle carrier (33) at front	Installation: Replace bolts (34).
			*BA33.10-P-1001-01I
43	Lower engine using front axle carrier (33)
44	Install in the reverse order
45	Fill power steering pump and bleed		AR46.30-P-0010GZ
46	Fill cooling system		AR20.00-P-1142GZ
47	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
48	Check engine oil level		AR18.00-P-3035-01GZ
			Figure
			*BF18.00-P-1001-03U
			*BF18.00-P-1002-03U
			*BF18.00-P-1003-03U
			*BF18.00-P-1004-03U
49	Check oil level in transmission and correct if necessary		AR27.00-P-0100W
50	Carry out engine test run and check engine for proper operation and leaktightness
51	Perform a wheel alignment check		AR40.20-P-0200GZ

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-1002-01A	Bolt, fuel distributor to intake manifold	Nm	10

STEERING SHAFT

Number	Designation		Model 164.1/8
BA46.10-P-1001-01J	Bolt, steering coupling to steering shaft	Nm	33

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

FRONT AXLE BRAKE CALIPER

Number	Designation		Model 164 except 164.177
BA42.10-P-1002-10L	Guide pin on caliper support	Nm	55

FRONT AXLE RPM SENSOR

Number	Designation		Model 164.1/8
BA42.30-P-1001-01G	Self-locking bolt, front axle RPM sensor to steering knuckle	Nm	8

FRONT AXLE STABILIZER BAR

Number	Designation			Model 164.1/8
BA32.20-P-1004-02L	Nut, link rod to stabilizer bar	Stage 1	Nm	100
		2nd stage loosen	∠°	180
		Stage 3	Nm	45
		Stage 4	∠°	60

WHEEL LOCATION, HUB

Number	Designation			Model 164.1/8
BA33.20-P-1001-01J	Self-locking nut, upper wishbone follower joint to steering knuckle	Stage 1	Nm	20
BA33.20-P-1001-01J		Stage 2	∠°	90

FRONT AXLE SHOCK ABSORBER

Number	Designation		Model 164.1/8
BA32.25-P-1002-01G	Self-locking nut, shock absorber to wishbone	Nm	265

FRONT AXLE CARRIER

Number	Designation				Model 164.1/8 except 164.177
BA33.10-P-1001-01I	Bolt, front axle carrier to longitudinal member	M14 X 1.5	Stage 1	Nm	100
			Stage 2	∠°	120
			Stage 3	∠°	-180
			Stage 4	Nm	100
			Stage 5	∠°	90
BA33.10-P-1002-01I	Bolt, stiffening plate to longitudinal member	M10		Nm	61
BA33.10-P-1003-01I	Bolt, stiffening plate to body	M8		Nm	31

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