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Remove/install engine with front axle carrier - AR01.10-P-2500GZB

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ENGINES 642 in MODEL 164 

Fig 1: Removing/Installing Engine With Front Axle Carrier (1 Of 4)
G00544407Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Removing/Installing Engine With Front Axle Carrier (2 Of 4)
G00544408Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Removing/Installing Engine With Front Axle Carrier (3 Of 4)
G00544409Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Removing/Installing Engine With Front Axle Carrier (4 Of 4)
G00544410Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REMOVINGINSTALLING Remove/install    
DANGER 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
DANGER 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
DANGER 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 Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Deactivate easy entry/exit function With lowered driver seat, code 275
For model 164 with 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. Deactivation ensues via the buttons on steering wheel in the "Comfort" menu of multifunction display.		  
DANGER Risk of explosion  caused by escaping oxyhydrogen gas. Risk of injury  caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries  caused by short circuit. Risk of poisoning  caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices No fire, sparks, open flames or smoking. Wear acid-resistant gloves and clothing and safety glasses with side guards. Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground. Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers. AS54.10-Z-0001-01A
2 Disconnect battery ground line Insulate ground line as a protection against unintentional contact of detached ground line with ground point of battery. AR54.10-P-0003GZ
NOTES Notes on battery   AH54.10-P-0001-01A
3 Removes strut tower brace Model 164.8 only AR62.30-P-2500GY
4 Remove engine trim panel    
5 Remove intake air ducts upstream of air filter    
6 Remove charge air hose upstream of charge air cooler   AR09.41-P-8621GZB
7 Remove charge air hose downstream of the charge air cooler   AR09.41-P-8625GZB
8 Remove wheels on front axle   AP40.10-P-4050Z
9 Remove bottom section of soundproofing   AR94.30-P-5300GZ 
10 Remove front wheel well lining Remove both sides. AR88.10-P-1300GZ
11 Disconnect engine wiring harness   AR01.00-P-2410GZB 
12 Detach vacuum hose (1) on vacuum pump (2)    
13 Suction off hydraulic fluid from the expansion reservoir of power steering (3) SPECIAL TOOL Hand pump Fig 6
    FLUID SPECIFICATION *BF46.20-P-1001-01C 
14 Detach hydraulic line (4) at power steering expansion reservoir (3) TORQUE SPECIFICATION *BA46.30-P-1006-01J 
    SPECIAL TOOL Set of stop plugs Fig 5
15 Drain coolant at radiator   AR20.00-P-1142GZB
NOTES Notes on coolant   AH20.00-N-2080-01A
16 Detach coolant hose (5, 6) at thermostat housing (7) Check condition of coolant hoses (5, 6), hose clamp and sealing ring; replace if necessary.  
17 Disconnect coolant hoses (8, 9) at connection fitting (10) Inspect condition of coolant hoses (8, 9) and hose clamps; replace if necessary.  
18 Remove oil cooler lines from automatic transmission on radiator connections (11) Seal all connections immediately.  
    SPECIAL TOOL Set of stop plugs Fig 5
19 Remove lines for power steering on radiator Seal all connections immediately  
    SPECIAL TOOL Set of stop plugs Fig 5
20 Fix steering wheel in center position Installation:  For model 164 with memory package (driver seat, steering column, mirrors), code 275, the holding device on the steering wheel must be taken away before connecting up the battery.  
    SPECIAL TOOL Holding device Fig 7
21 Disconnect steering shaft (16) on universal joint (17) The bolt (18) must be completely unscrewed since it is fed into a groove.  
    TORQUE SPECIFICATION *BA46.10-P-1001-01J 
22 Loosen poly-V belt (13) Remove poly-V belt (13) from belt pulley on refrigerant compressor (A9) and power steering pump (3b). AR13.20-P-0001GZB
23 Remove refrigerant compressor (A9) from timing case cover by removing bolts (14) Disconnect connector on refrigerant compressor (A9). Attach refrigerant compressor (A9) with connected pipe system laterally at bottom of engine compartment.  
    TORQUE SPECIFICATION *BA83.55-P-1001-01R 
24 Remove power steering pump (3b) TORQUE SPECIFICATION *BA46.30-P-1001-01J 
25 Remove exhaust system   AR49.10-P-7100GZB
26 Detach rear propeller shaft (36) from transfer case (35) Mark propeller shaft (36) relative to propeller shaft flange (14a).
Installation:  Observe tightening procedure for rear propeller shaft (36) to transfer case (35).		 AR41.10-P-0050GZ
27 Remove heat shield (15) Only for offroad package, code 430  
28 Disconnect electrical connectors (15a) on transfer case Only for offroad package, code 430
Three connectors.		  
29 Remove left and right underfloor paneling   AR61.30-P-1001GZ
30 Disconnect right front brake pad contact sensor connector on brake caliper (26)    
31 Remove guide pin (20) and brake caliper (26) Secure brake caliper (26) with attached lines to upper transverse control arm (25).
Installation:  Replace guide bolts (20).		  
    TORQUE SPECIFICATION *BA42.10-P-1002-10L 
32 Remove bracket (21) Installation:  Install new cable ties.  
33 Unscrew left front RPM sensor (L6/1) and or right front RPM sensor (L6/2) on wheel carrier Fasten all lines using a cable tie to suspension strut on corresponding side.  
    TORQUE SPECIFICATION *BA42.30-P-1001-01G 
34 Remove nut (23) on stabilizer bar (22) link rod TORQUE SPECIFICATION *BA32.20-P-1004-02L 
35 Remove nut (24) on transverse control arm (25) TORQUE SPECIFICATION *BA33.20-P-1001-01J 
    SPECIAL TOOL Puller Fig 8
    SPECIAL TOOL Thrust piece Fig 9
36 Installation:  Final tightening if vehicle on measuring platform or in K0 position, in order to avoid placing the rubber mount under stress.    
    TORQUE SPECIFICATION *BA32.25-P-1002-01G 
37 Secure vehicle on lifting platform against falling over SPECIAL TOOL Lifting platform retainer Fig 10
38 Position portable lifting platform with universal assembly mount on front axle carrier 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! Vehicle lift for major assemblies/scissors-type pallet forklift		  
39 Remove bolts (27) on engine crossmember (28) TORQUE SPECIFICATION *BA22.10-P-1005-03G 
NOTES 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 screw/bolt (29).  
    TORQUE SPECIFICATION *BA33.10-P-1001-01I 
41 Remove bolts M10 (30) and bolts M8 (31) on stiffening plates (32) Installation:  Replace bolts M10 (30) and bolts M8 (31).  
    TORQUE SPECIFICATION *BA33.10-P-1003-01I 
42 Remove bolts (34) on front axle carrier (33) at front Installation:  Replace screw/bolt (34).  
    TORQUE SPECIFICATION *BA33.10-P-1001-01I 
43 Lower engine using front axle carrier (33)    
44 Install in the reverse order    
45 Fill cooling system   AR20.00-P-1142GZB
46 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-1010GZB
47 Check engine oil level In order to avoid measurement errors, vehicle must be parked on an even surface.
Shut off engine once it has reached operating temperature and wait approx. 5 minutes before checking engine oil level.		 AR18.00-P-3035-01PI
    FLUID SPECIFICATION Without particulate filter *BF18.00-P-1001-01A 
    FLUID SPECIFICATION With code 474 Particulate filter *BF18.00-P-1001-01S 
48 Check transmission oil level and correct if necessary   AR27.00-P-0270W
49 Perform wheel alignment check   AR40.20-P-0200GZ
50 Read out fault memory and erase if necessary Stored fault entries which may be caused by disconnecting cables or by simulation during removal and installation or inspection operations, must be erased from the fault memory after work is completed. AD00.00-P-2000-04A
POWER STEERING PUMP

Number Designation Model 164.1/8 with engine 642
BA46.30-P-1001-01J Bolt, power steering pump to control housing M8X20 Nm 20
M8X30 Nm 20
M8X34 Nm 35
M8X44 Nm 35
BA46.30-P-1006-01J Clamp, hydraulic line to power steering pump reservoir Nm 2
REFRIGERANT COMPRESSOR

Number Designation Model 164.1/8
BA83.55-P-1001-01R Bolt, refrigerant compressor to timing case and left engine support Nm 20
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 BRAKE CALIPER

Number Designation Model 164.1/8
BA42.10-P-1002-10L Guide pin on caliper support Nm 55
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
Stage 2 loosen ∠° 180
Stage 3 Nm 120
Stage 4 ∠° 45
WHEEL CONTROL, HUB

Number Designation Model 164.1/8
BA33.20-P-1001-01J Self-locking nut, upper ball joint out of upper transverse control arm to steering knuckle Stage 1 Nm 20
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
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

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

Number Designation Model 164.1/8 except 164.177
BA33.10-P-1001-01I Bolt, front axle carrier to longitudinal member M14 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
STEERING SHAFT

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

Number Designation Model 164
BF46.20-P-1001-01C Power steering Filling capacity Liters ≈1.2
MB steering gear oil Sheet BB00.40-P-0236-03A
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642 without particulate filter
BF18.00-P-1001-01A Engine oil Filling capacity
(oil and filter change)		 Liters 8.5
Specifications for Operating Fluids Sheet BB00.40-P-0228-03A 
Sheet BB00.40-P-0228-05A 
Sheet BB00.40-P-0228-51A 
Sheet BB00.40-P-0229-03A 
Sheet BB00.40-P-0229-31A 
Sheet BB00.40-P-0229-05A 
Sheet BB00.40-P-0229-51A 
ENGINE LUBRICATION SYSTEM

Number Designation Engine 642 with particulate filter
BF18.00-P-1001-01S Engine oil Filling capacity
(oil and filter change)		 Liters 8.5
Specifications for Operating Fluids Sheet BB00.40-P-0228-51A 
Sheet BB00.40-P-0229-31A 
Sheet BB00.40-P-0229-51A 
Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)
G07765382Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 6: Identifying Hand Pump (210 589 00 71 00)
G07741018Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 7: Identifying Holding Device (129 589 01 21 00)
G07741017Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 8: Identifying Puller (601 589 04 33 00)
G07744815Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 9: Identifying Thrust Piece (140 589 00 63 00)
G07510541Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 10: Identifying Vehicle Hoist Securing Tool (169 589 02 31 00)
G07210911Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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