Remove/install engine with front axle carrier - AR01.10-P-2500GZS (ML63 AMG)

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ENGINE 156 in MODEL 164, 251

Fig 1: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 156 (1 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 156 (2 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 156 (3 Of 4)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Engine With Front Axle Carrier Remove/Install Components - Engine 156 (4 Of 4)

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 35

	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, tailgates or sliding roof.	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	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
	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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Move DIRECT SELECT gear selector switch to position "N"
2	Release parking brake
3	Deactivate easy entry/exit function	Vehicles with memory package (driver seat, steering column, mirrors), code 275. Otherwise the driver seat and steering wheel move into a different position if the driver door is opened or closed for example. The upper frame may be damaged when the holding device is installed. Deactivation ensues via buttons on the steering wheel in the "Comfort" menu of the multifunction display.
4	Turn key in ignition lock to position "0"	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).
5	Disconnect battery ground cable	Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery.
		Model 164	AR54.10-P-0003GZ
		Model 251	AR54.10-P-0003RT
	Notes on battery		AH54.10-P-0001-01A
6	Fix steering wheel in center position		Figure
7	Secure vehicle on the lifting platform	Model 164	AR00.60-P-0100GZ
		Model 251	AR00.60-P-0100RT
8	Remove wheels on the front axle
	Remove/install wheels	Model 251	AP40.10-P-4050RT
	Remove/install wheels	Model 164	AP40.10-P-4050Z
9	Completely remove front wheelhouse panels	Model 164:
		Rear section	AR88.10-P-1300GZ
		Front section	AR88.10-P-1310GZ
		Model 251:
		Rear section	AR88.10-P-1300RT
		Front section	AR88.10-P-1310RT
10	Remove left and right underfloor paneling	Model 164	AR61.30-P-1001GZ
		Model 251	AR61.30-P-1001RT
11	Remove air filter housing		AR09.10-P-1150GZS
	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
12	Dismount fuel line (1) from fuel distributor	Release fuel pressure with pressure hose via service valve	AR07.03-P-1460-01TMG
			*BA07.03-P-1001-01C
			Figure
13	Discharge air conditioning system	Vehicles with automatic air conditioning, code 580 and comfort automatic air conditioning, code 581 Installation: Replace desiccant cartridge.
		Model 164	AR83.30-P-1760GZ
		Model 251	AR83.30-P-1760RT
14	Suction off hydraulic fluid from the expansion reservoir of power steering (2)		Figure
15	Remove bottom engine compartment paneling	Model 164	AR61.20-P-1105GZ
		Model 251	AR61.20-P-1105RT
16	Drain engine oil
17	Drain coolant at radiator		AR20.00-P-1142GZS
	Notes on coolant		AH20.00-N-2080-01A
18	Disconnect lines on oil/water heat exchanger (1a) in right front wheel well	Model 251 only Unclip coolant hoses (6a). Unscrew bolts (2a) and nut (3a) on brackets (4a, 5a). Remove bracket (5a) and remove oil/water heat exchanger (1a) completely with bracket (4a).
19	Disconnect coolant hose (3) at engine radiator (4) at top	Check condition of coolant hose (3) and hose clamp; replace if necessary.
20	Disconnect vent line (5) at distributor (6)	Check condition of vent line (5) and replace if necessary.
21	Remove air line (7) for additional air pump completely
22	Release hydraulic lines (8, 9) at top of power steering	Seal all connections immediately.
			Figure
23	Remove refrigerant lines at connectors (10, 11) on refrigerant compressor (A9)	Installation: Replace the gaskets.
		Model 164	AR83.55-P-5300GZ
		Model 251	AR83.55-P-5300RT
24	Disconnect hose (12) at purge line (13) on engine at the left front
25	Remove brake booster vacuum line (14) at intake manifold	Remove clip and lay brake booster (14) vacuum line to one side.
26	Disconnect steering shaft (15) on universal joint (16)	The bolt (17) must be completely unscrewed since it is fed into a groove.
		Model 164	*BA46.10-P-1001-01J
		Model 251	*BA46.10-P-1001-01K
27	Dismount coolant hose (18) for heat exchanger at firewall (19) connection	Check condition of coolant hose (18) and hose clamp; replace if necessary.
28	Unclip upper transmission oil cooler line at engine radiator (4) above from bracket and disconnect	Seal off connection immediately.	AR27.10-P-0501-03RT
			Figure
29	Disconnect engine wiring harness	Model 164	AR01.00-P-2410GZS
		Model 251	AR01.00-P-2410RTS
30	Disconnect ground line at alternator	Model 164 only
31	Disconnect engine oil lines (20) at flange connections (21)	Installation: Replace sealing rings.
32	Remove coolant hose at connection fitting (23) of coolant pump (24)	Check condition of coolant hose and hose clamp, replace if required.
33	Disconnect transmission oil cooler line (22) at engine radiator (4)	Seal off connection immediately.	AR27.10-P-0501-03RT
			Figure
34.1	Remove exhaust system	Model 164	AR49.10-P-7000GZS
34.2	Remove exhaust system up to rear flange connection	Model 251	AR49.10-P-7000RT
35	Detach rear propeller shaft from transfer case (25)	In addition on model 251: Remove the cross strut below the rear propeller. Mark the rear propeller shaft relative to the propeller shaft flange. Unscrew bolts from vibration damper on transfer case (25), then push the vibration damper over the rear propeller shaft.
		Installation: Observe tightening procedure for rear propeller shaft to transfer case (25).	AR41.10-P-0050-17GZ
			Figure
		Model 164	*BA41.10-P-1001-01F
		Model 251	*BA41.10-P-1001-01G
36	Unscrew left front RPM sensor (L6/1) and or right front RPM sensor (L6/2) on wheel carrier	Fasten all electrical lines with a cable tie to suspension strut on corresponding side.
		Model 164	AR42.30-P-0712GZ
		Model 251	AR42.30-P-0712RT
37	Unplug connector for speed-sensitive power steering
38	Remove control rod for Xenon or level control at lower ball head
39	Disconnect right front brake pad contact sensor connector
40	Remove bracket (26)	Installation: Install new tie straps.
41	Unclip outer tension spring, remove guide pins (27) and remove brake caliper (28)	On both sides. Fasten brake caliper with line connected to upper transverse control arm (29). Installation: Replace guide bolts (27).
			*BA42.10-P-1002-10L
42	Unscrew nut (30) on link rod of stabilizer bar (31)	On both sides.
		Model 164	AR32.20-P-0300GZ
		Model 251	AR32.20-P-0300RT
43	Unscrew nut (32) on upper transverse control arm (29)	On both sides.
		Model 164	*BA33.20-P-1001-01J
		Model 251	*BA33.20-P-1001-01L
			Figure
			Figure
44	Remove shock-absorber struts (33) at lower transverse control arm	On both sides.
		Model 164	AR32.25-P-1017GZ
		Model 251	AR32.25-P-1017RT
45	Position portable lifting platform with universal major assembly support at front axle carrier (40) 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) see GOTIS http://gotis.aftersales.daimlerchrysler.com Universal main assembly mount see GOTIS http://gotis.aftersales.daimlerchrysler.com
46	Remove bolts (34) on engine crossmember (35)	Model 164	*BA22.10-P-1005-03G
		Model 251	*BA22.10-P-1005-03F
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
47	Remove bolts (36, 37, 38) at front axle carrier (40) and at stiffening plate (39)	Installation: Replace bolts (36, 37, 38). Model 164
			*BA33.10-P-1001-01I
			*BA33.10-P-1002-01I
		Model 251	*BA33.10-P-1003-01I
			*BA33.10-P-1001-01L
			*BA33.10-P-1002-01L
			*BA33.10-P-1003-01L
48	Lower engine using front axle carrier (40)
49	Install in the reverse order
50	Fill cooling system		AR20.00-P-1142GZS
51	Inspecting cooling system for leaks		AR20.00-P-1010GZS
52	Fill power steering pump and bleed	Model 164	AR46.30-P-0010GZ
		Model 251	AR46.30-P-0010RT
53	Check engine oil level	Engine oil	*BF18.00-P-1001-01V
54	Check oil level in transmission and correct if necessary		AR27.00-P-0100W
55	Read out fault memory and erase if necessary	Stored faults which may be caused by disconnecting cables or by simulation during test operations, must be erased in the fault memory after completing the work.
56	Perform a wheel alignment check	Model 164	AR40.20-P-0200GZ
		Model 251	AR40.20-P-0200RT
57	Carry out engine test run and check engine for proper operation and leaktightness

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		Engine 156
BA07.03-P-1001-01C	Union nut, fuel feed line to fuel distributor	Nm	20

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

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 BRAKE CALIPER

Number	Designation		Model 164.177	Model 251.077 / 177
BA42.10-P-1002-10L	Guide pin on caliper support	Nm	30	30

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

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 164
BA22.10-P-1005-03G	Bolt, rear engine crossmember to body	Nm	55

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 251
BA22.10-P-1005-03F	Bolt, rear engine crossmember to body	Nm	55

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

FRONT AXLE CARRIER

Number	Designation				Model 251
BA33.10-P-1001-01L	Self-locking bolt, front axle carrier (front) to longitudinal member	M14X1.5	Stage 1	Nm	130
			Stage 2	∠°	-180
			Stage 3	Nm	100
			Stage 4	∠°	45
BA33.10-P-1002-01L	Self-locking bolt, front axle carrier at rear to longitudinal member	M14 X 1.5	Stage 1	Nm	130
			Stage 2	∠°	-180
			Stage 3	Nm	100
			Stage 4	∠°	90
BA33.10-P-1003-01L	Bolt, stiffening plate to longitudinal member	M10		Nm	61

ENGINE LUBRICATION SYSTEM

Number	Designation			Engine 156 in model 164	Engine 156 in model 251
BF18.00-P-1001-01V	Engine oil	Filling capacity (oil and filter change)	Liters	9, 7	9, 6
		Specifications for Operating Fluids	Sheet
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-05 A	BB00.40-P-0229-0 5A