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

ENGINES 157, 278 in MODEL 216, 221 

ENGINES 276 in MODEL 221.082/182 

Shown on model 216.373 with code (487) 

Active Body Control (ABC) 

Shown on model 216.373 with code (487) 

Active Body Control (ABC) 

Shown on model 221.074 with code (487) 

Active Body Control (ABC) 

Shown on model 216.373 with code (487) 

Active Body Control (ABC) 

Shows model 221.094 

27.7.10

Value changed: fuel line union nut on fuel distributor

*BA07.03-P-1001-01E

	Remove/install
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on Active Body Control suspension		AH32.50-P-0001-01N
	Notes on AIRmatic		AH32.22-P-1000-02SX
		The ground line on the battery must always  be detached before beginning work on the fuel system otherwise pressure will be built up in the fuel system through opening a vehicle door or the trunk lid
		Tighten nuts and bolts of chassis components only when vehicle is in the ready-to-drive condition.
1	Reduce pressure in front suspension struts to zero using STAR DIAGNOSIS	Vehicles with AIRmatic	AD00.00-P-2000-04A
2	Deactivate easy entry/exit function	Vehicles with memory package (driver seat, steering column, mirrors) code 275	AR54.30-P-1000-02ESX
3	Turn front wheels to straight-ahead position and secure steering wheel with holding device	The steering wheel must not be turned when the steering coupling is detached, otherwise the clock spring contact will be destroyed.
			Figure
4	Set DIRECT SELECT gear selector switch to position "N" and release parking brake
5	Detach ground line from battery		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
6	Secure vehicle on vehicle lift		AR00.60-P-0100SX
7	Remove bottom engine compartment paneling		AR61.20-P-1105SX
8	Drain coolant at radiator		AR20.00-P-1142MM
	Notes on coolant		AH20.00-N-2080-01A
9	Remove engine trim panels (2)
10	Remove both engine air intake ducts (3) upstream of the air filter housings (4)
11	Remove both air filter housings (4)
12	Remove insulation (5) on rail
13	Suction refrigerant out of air conditioning	See "Drain air conditioning system, evacuate, refill and check for proper operation and leaktightness".	AR83.30-P-1760SX
14	Extract oil from ABC expansion reservoir	Vehicles with code (487) Active Body Control (ABC)
			Fig 11
15	Extract oil from power steering expansion reservoir		Fig 11
16	Disconnect refrigerant line (6) in engine compartment at connecting point	Seal openings using stop plugs.
			Fig 9
17	Detach purge line (11) on purge control valve (Y58/1)
18	Remove center bulkhead (7)
19	Detach vacuum line on intake manifold and vacuum pump and place to one side	Engine 157, 278	AR43.05-P-1320MMB
		Engine 276	AR43.05-P-1320MMA
20	Disconnect engine wiring harness on the vehicle side	Engine 157, 278	AR01.00-P-2410-02MMB
		Engine 276	AR01.00-P-2410-02MMA
21	Detach electrical line on intelligent servo module (A80) and unclip on transmission		AR27.19-P-0550SX
22	Disconnect electrical line at electrical transmission oil pump (M42) and unclip on transmission	See "Remove auxiliary oil pump for AT".	AR27.30-P-0651SXH
23	Remove shield and disconnect electrical connector for transmission control		AR27.40-P-0700-01SX
			*BA27.40-P-1014-01A
24	Remove catalytic converters	See: "Remove components of exhaust system".	AR49.10-P-7100SX
25	Detach electrical line on speed-sensitive power steering solenoid valve and unclip on front axle carrier (31)	See "Remove rack-and-pinion steering".	AR46.20-P-0600SX
26	Detach coolant hose (12)) on heater shutoff valve (10)
27	Detach coolant hose on coolant pump and cooler	Lay coolant hose to the side.
		See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
28	Detach coolant hoses (15, 16) at coolant lines (17, 18) for charge air cooler
29	Detach coolant hose at thermostat housing	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
30	Detach refrigerant line on condenser	Seal openings using stop plugs.	AR83.30-P-6540SX
			Fig 9
31	Drain off hydraulic fluid in the front suspension strut over the bleed screws and catch in a suitable container	Vehicles with code (487) Active Body Control (ABC) Bleed screws: ↓
		Observe note about Active Body Control suspension.	AH32.50-P-0001-01N
32	Disconnect pressure line D1 from return line R1 for the P/S at connecting point	See "Remove hydraulic line for P/S". Seal openings using stop plugs.	AR46.25-P-3015SXH
			Fig 9
			Fig 10
33	Loosen wheelhouse paneling for the right front fender in the front lower area	Vehicles with code (487) Active Body Control (ABC)
34	Disconnect front right ABC hydraulic line at connecting point and remove at longitudinal member	Vehicles with code (487) Active Body Control (ABC)	AR32.50-P-0024SX
35	Detach front right ABC hydraulic line and hydraulic line for ABC pump at ABC front axle valve unit	Vehicles with code (487) Active Body Control (ABC)	AR32.50-P-0001SX
36	Detach oil cooling line for transmission on cooler	Seal openings using stop plugs.	AR27.10-P-0501-03SX
			Fig 9
37	Detach oil lines for engine oil cooling on oil cooler	Engine 157 Seal openings using stop plugs.
			Fig 9
38	Remove heat shield over the steering coupling and detach steering coupling on the lower steering shaft		AR46.10-P-8000SX
39	Remove front wheels		AP40.10-P-4050SX
40	Detach link rods from stabilizer bar	Model 221 with AIRmatic The torsion bar remains on the front axle carrier (31).	AR32.20-P-0300SX
			*BA32.20-P-1001-02O
	Operation steps 41 to 46 only for vehicles without 4MATIC
41	Remove tie rods from steering knuckles		AR46.40-P-0200SX
42	Detach ABC front axle valve unit from retaining plate	Vehicles with code (487) Active Body Control (ABC)	AR32.50-P-0001SX
43	Detach strut rods from front axle carrier (31)		AR33.15-P-0160SX
44	Detach spring control arm from front axle carrier (31).	Vehicles with AIRmatic	AR33.15-P-0170SX
		Vehicles with code (487) Active Body Control (ABC)	AR33.15-P-0170SY
45	Detach rpm sensor bracket at steering knuckle and spring control arm	Vehicles with code (487) Active Body Control (ABC)	AR42.30-P-0712SX
46	Loosen nuts or bolts for the suspension struts below on spring control arms	Vehicles with AIRmatic	AR32.25-P-1017SX
		Vehicles with code (487) Active Body Control (ABC)	AR32.25-P-1017SY
	Operation steps 47 to 51 only for vehicles with 4MATIC
47	Disconnect electrical connector from rpm sensors, right front brake pad contact sensor and damping valve unit connector for front axle on left and right	Unclip electrical lines from brackets.	AR33.10-P-0100-06SX
48	Detach brake caliper from brake caliper support	Fix brake caliper with attached lines to upper transverse control arms using cable ties.
			*BA42.10-P-1005-10M
49	Remove upper transverse control arm from steering knuckles		AR33.20-P-0500-01SX
			*BA33.20-P-1007-01M
			Fig 12
			Fig 13
50	Detach suspension struts from spring control arms		*BA32.25-P-1007-04L
51	Remove bracket (24) for the lower engine compartment paneling
52	Disconnect bleed line (19) at connecting point
53	Disconnect feed hose for the ABC hydraulic pump on connecting point on the cylinder head cover	Vehicles with code (487) Active Body Control (ABC)
54	Detach return line (20) at power steering expansion reservoir		AR46.25-P-1000SXH
55	Reduce fuel pressure through service valve		AR07.03-P-1460-01VA
		Engine 276	*BA07.03-P-1007-01D
		Engines 157, 278	*BA07.03-P-1007-01E
			Fig 8
56	Detach fuel line (8) on fuel distributor (9)	Seal openings using stop plugs.
		Engine 276	*BA07.03-P-1001-01D
		Engines 157, 278	*BA07.03-P-1001-01E
			Fig 9
57	Support front axle carrier (31) with lifting platform and aggregate mount and secure whole engine transmission unit against slipping and falling down with a tensioning strap	Ensure even alignment of support plates.
		Major assembly lifting platform/scissors-type pallet forklift
58	Remove screw/bolts (23a) and rear engine crossmember (23) with rear engine mount.	Vehicles without 4MATIC	AR22.10-P-1180SX
		Vehicles with 4MATIC	AR22.10-P-1180SW
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
59	Detach drive shaft (22) from transmission output flange/transfer case	Apply colored identification of propeller shaft position relative to transmission output flange in order when installing to reproduce installation position created at plant as otherwise drive line vibrations can occur.	AR41.10-P-0050-02SX
		Mount propeller shaft (22) on transmission output flange.	AR41.10-P-0050-07SX
			*BA41.10-P-1001-01H
60	Remove screw/bolts (31a) of longitudinal members	Replace bolts (31a).
		Vehicles without 4MATIC	AR33.10-P-0100SX
		Vehicles with 4MATIC	AR33.10-P-0100SYZ
61	Lower engine transmission unit with front axle carrier (31)	Ensure that engine does not touch any body parts or components and that no lines are pinched or damaged.
62	Install in the reverse order
63	Inspect cooling system for leaks		AR20.00-P-1010SX
64	Fill and bleed active body control (ABC)	Vehicles with code (487) Active Body Control (ABC)	AR32.50-P-0021SX
65	Fill and bleed the power steering		AR46.30-P-0010SX
66	Correct transmission oil level	Vehicles without 4MATIC	AR27.00-P-0270W
		Vehicles with 4MATIC	AR27.00-P-0270SYZ
67	Perform wheel alignment check		AR40.20-P-0200SX
68	Read out fault memory with STAR DIAGNOSIS and erase if necessary		AD00.00-P-2000-04A
	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
69	Carry out engine test run, checking the engine for proper operation and leaks

Number	Designation			Engine 157	Engine 278
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor		Nm	22	22
BA07.03-P-1007-01E	Protective cap on service valve	Plastic	Nm	2	2
		Metal	Nm	15	15

Number	Designation			Engine 276
BA07.03-P-1001-01D	Union nut, fuel line to fuel distributor		Nm	22
BA07.03-P-1007-01D	Protective cap on service valve	Plastic	Nm	2
		Metal	Nm	15

Number	Designation			Model 216	Model 221
BA41.10-P-1001-01H	Self-locking nut, flex disk to transmission or front propeller shaft	M12	Nm	68	68

Number	Designation		Transmission 722.9
BA27.40-P-1014-01A	Screw/bolt, heat shield to transmission housing	Nm	9

Number	Designation			Model 216 with 4MATIC	Model 221.08/09/18/19 with 4MATIC without code Z07
BA33.20-P-1007-01M	Self-locking nut, upper ball joint out of upper transverse control arm to steering knuckle	Stage 1	Nm	20	20
		Stage 2	∠°	90	90

Number	Designation		Model 216 except model 216.374/377/379	Model 221 except model 221.074/077/174/177/179
BA42.10-P-1005-10M	Self-locking bolt, caliper support to steering knuckle	Nm	180	180

Number	Designation			Model 216 with 4MATIC	Model 221 with 4MATIC
BA32.25-P-1007-04L	Nut, front suspension strut to spring control arm	M14	Nm	110	110
		M16	Nm	-	-

Number	Designation		Model 216	Model 221
BA32.20-P-1001-02O	Nut, link rod to stabilizer bar	Nm	90	90