Remove/install engine with front axle carrier - AR01.10-P-2500GZA (ML350, ML550, GL450, GL550)

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ENGINE 272, 273 in MODEL 164, 251

Fig 1: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (1 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (2 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (3 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (4 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (5 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 272, 273 (6 Of 6)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

25.6.07

Observe tightening procedure when assembling propeller shaft, added

Step 28

	Remove/install
	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
	For vehicles with code 275, Memory package (driver seat, steering column, mirrors), the easy entry/exit function must be disabled otherwise damage can occur on reconnection of battery, since the driver seat and steering wheel will be moved to another position if, for example, the driver door is opened or closed. The system is deactivated in the "Comfort" menu of multifunction display using buttons on steering wheel
Installation	Only tighten nuts and bolts of chassis components when vehicle is in a ready-to-drive condition.
1	Set DIRECT SELECT gear selector switch to position "N" and release parking brake
2	Bring front wheel into straight-ahead position and fix steering wheel in center position	The steering wheel must not be turned when the steering coupling is detached, otherwise the clock spring contact will be destroyed.
			Figure
3	Secure vehicle on the lifting platform	Model 164	AR00.60-P-0100GZ
		Model 251	AR00.60-P-0100RT
4	Disconnect battery ground cable	Model 164	AR54.10-P-0003GZ
		Model 251 Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery.	AR54.10-P-0003RT
	Notes on battery		AH54.10-P-0001-01A
		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).
5	Remove air filter housing (3) with engine intake air ducts (1)		AR09.10-P-1150GZA
6	Suction refrigerant out of air conditioning	Engine 273
7	Disconnect engine wiring harness		AR01.00-P-2410GZA
8	Remove left O2 sensor downstream of TWC	Engine 272 Required for removal of exhaust system.	AR07.52-P-5303GZP
9	Remove complete exhaust system		AR49.10-P-7100GZA
10	Detach purge line (4) from purge switchover valve and on vacuum line for crankcase ventilation system (5)
11	Disconnect brake booster vacuum line (6) on intake manifold
12	Extract leak oil from power steering expansion reservoir (10)		Figure
13	Remove power steering (14) return line at power steering (10) expansion reservoir	Installation: Replace hose clamp.
14	Remove power steering (15) return line at engine radiator (19)	Installation: Replace hose clamp.
15	Remove transmission oil lines (17, 18) at radiator (19)		Figure
16	Remove poly-V belt (20)	Only for engine 272	AR13.20-P-0001GZA
17	Remove coolant compressor (A9) from timing case cover and engine support, to do this unscrew the bolts (21)	Only for engine 272
		Model 164	AR83.55-P-5300GZ
		Model 251 Remove refrigerant compressor connector (A9x1) on refrigerant compressor (A9). Attach refrigerant compressor (A9) with connected pipe system laterally at bottom of engine compartment.	AR83.55-P-5300RT
		Installation: Move refrigerant compressor (A9) into installation position and mount timing case cover and engine support, before the motor is moved completely into the engine compartment.
18	Remove bolt (24) and take off steering coupling from bottom steering shaft (22)	Model 164	*BA46.10-P-1001-01J
		Model 251	*BA46.10-P-1001-01K
19	Remove refrigerant line (33) at refrigerant compressor (A9) and refrigerant line (34) at separation point	Only for engine 273
		Model 164	AR83.55-P-5300GZ
		Model 251	AR83.55-P-5300RT
20	Release fuel pressure over service valve (7)	Collect escaping fuel.	AR07.03-P-1460-01GZ
			Figure
21	Remove fuel feed line (8) on fuel distributor (9)	Collect feathering-out fuel and seal connections.
			*BA07.03-P-1001-01B
			Figure
22	Drain coolant at radiator (19)		AR20.00-P-1142GZC
	Notes on coolant		AH20.00-N-2080-01A
23	Disconnect coolant line (25) from heater heat exchanger connection (26)
24	Dismount coolant line (27) at thermostat housing (28)	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
25	Remove coolant line (29) on coolant pump (30)	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
26	Unscrew bolts from the stiffening bridge under the propeller shaft	Only for model 251
			*BA61.10-P-1005-01F
27	Mark propeller shaft to propeller shaft flange on transfer case/ adapter housing
28	Remove rear propeller shaft at transfer case/ adapter housing	Installation: Observe tightening procedure for rear propeller shaft to transfer case/ adapter housing.	AR41.10-P-0050-17GZ
			Figure
		Model 164	*BA41.10-P-1001-01F
		Model 251	*BA41.10-P-1001-01G
29	Remove wheels on the front axle
	Remove/install wheels	Model 164	AP40.10-P-4050Z
		Model 251	AP40.10-P-4050RT
30	Remove front section for right and left wheelhouse covering
31	Remove left and right underfloor paneling
32	Remove bracket (36) from steering knuckles (37)	Installation: replace cable tie (38).
33	Remove left front RPM sensor and right front RPM sensor (L6/1, L6/2) from steering knuckle (37)	Unclip electrical lines of RPM sensors from brackets. Fasten all lines using a cable tie to suspension strut on corresponding side.
		Model 164	*BA42.30-P-1001-01G
		Model 251	*BA42.30-P-1001-01I
34	Remove guide pins (39) and brake calipers (40) from brake caliper supports	Fix brake caliper with attached lines to upper transverse control arms using cable ties.
		Model 164	AR42.10-P-0070GZ
		Model 251	AR42.10-P-0070RT
35	Detach link rods (41) from shock absorbers (42)	Model 164	*BA32.20-P-1003-02L
		Model 251	*BA32.20-P-1003-02N
36	Detach shock absorber (42) from lower transverse control arm (44)	Model 164	*BA32.25-P-1002-01G
		Model 251	*BA32.25-P-1002-01H
37	Detach upper transverse control arm (45) from steering knuckles (37)		Figure
			Figure
		Model 164	*BA33.20-P-1001-01J
		Model 251	*BA33.20-P-1001-01L
38	Prop front axle carrier (46) using lifting platform	Support front axle and transmission. When doing so ensure that mounting plates are correctly aligned. Before removal the complete unit must be secured against falling down 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	AR01.10-P-2500-01A
39	Remove rear engine crossmember (47) from frame floor assembly	Installation: Install new bolts.	AR22.10-P-1180GZD
40	Remove bolts (48) on stiffening plates (49) and bolts (50) on longitudinal members (51)	Model 164	AR33.10-P-0100GZ
		Model 251 Installation: Install new bolts.	AR33.10-P-0100RT
41	Lower engine transmission unit with front axle carrier (46)	For engine 272 ensure that refrigerant compressor (A9) does not get caught on power steering (10) expansion reservoir.
42	Install in the reverse order
43	Check engine oil level and correct if necessary
44	Fill and bleed power steering pump (11)	Model 164	AR46.30-P-0010GZ
		Model 251	AR46.30-P-0010RT
45	Check oil level in transmission and correct if necessary		AR27.00-P-0100W
46	Perform chassis alignment	Model 164	AR40.20-P-0200GZ
		Model 251	AR40.20-P-0200RT
47	Read out fault memory and erase if necessary	STAR DIAGNOSIS diagnostic system
	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

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 272 without code 917	Engine 272 with code 917	Engine 273
BA07.03-P-1001-01B	Union nut, fuel feed line to fuel distributor	Nm	20	20	20

FRONT AXLE STABILIZER BAR

Number	Designation			Model 164.1/8
BA32.20-P-1003-02L	Nut, link rod to front shock	Stage 1	Nm	100
		Stage 2 loosen	∠°	180
		Stage 3	Nm	120
		Stage 4	∠°	45

FRAME FLOOR ASSEMBLY

Number	Designation		Model 251
BA61.10-P-1005-01F	Bolt, stiffening bridge to frame floor assembly	Nm	20

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 SHOCK ABSORBER

Number	Designation		Model 251
BA32.25-P-1002-01H	Self-locking nut, shock absorber to wishbone	Nm	265

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

PROPELLER SHAFT

Number	Designation			Model 251
BA41.10-P-1001-01G	Self-locking bolt, propeller shaft to transfer case (to rear axle)	Stage 1	Nm	40
BA41.10-P-1001-01G		Stage 2	∠°	90

FRONT AXLE RPM SENSOR

Number	Designation		Model 251
BA42.30-P-1001-01I	Self-locking bolt, front axle RPM sensor to steering knuckle	Nm	8

FRONT AXLE STABILIZER BAR

Number	Designation		Model 251
BA32.20-P-1003-02N	Nut, link rod to front shock	Nm	200

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

WHEEL LOCATION, HUB

Number	Designation			Model 251
BA33.20-P-1001-01L	Self-locking nut, upper wishbone follower joint to steering knuckle	Stage 1	Nm	20
BA33.20-P-1001-01L		Stage 2	∠°	90

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

STEERING SHAFT

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

STEERING SHAFT

Number	Designation		Model 251
BA46.10-P-1001-01K	Bolt, steering coupling to steering shaft	Nm	33

Fig 7: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying Hand Pump (210 589 00 71 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Identifying Holding Device (129 589 01 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 11: Identifying Puller (601 589 04 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 12: Identifying Thrust Piece (140 589 00 63 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 13: Identifying Retainer Wrench (164 589 02 07 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.