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

ENGINE 272, 273 in MODEL 221 (except 221.08/18) 

ENGINE 273.961 in MODEL 216 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

Model 216 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

Shown on model 221.171 with code (487) Active Body Control (ABC) 

29.6.10

Value modified: Self-locking nut of flex disk to transmission or front propeller shaft, M12

*BA41.10-P-1001-01H

	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
		Tighten nuts and bolts of chassis components only when vehicle is in the ready-to-drive condition.
1	Set DIRECT SELECT gear selector switch to position "N" and release parking brake
2	Reduce pressure in front suspension struts to zero using STAR DIAGNOSIS Vehicles with AIRmatic
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
3	Deactivate easy entry/exit function	Vehicles with memory package (driver seat, steering column, mirrors) code 275	AR54.30-P-1000-02ESX
4	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
	Risk of death  when touching components on vehicles with high-voltage on-board electrical system	Do not touch components and open lines of the high-voltage on-board electrical system. Persons who are carriers of electronic implants (e.g. cardiac pacemakers), must not carry out any work on high-voltage on-board electrical systems.	AS54.00-Z-0001-01A
5	Perform disable for high-voltage on-board electrical system	Model 221.095/195 Include initial startup event log together with the disable power event log in the vehicle file after conclusion of the work.	AR54.10-P-1150SXH
	Note on high-voltage on-board electrical system		AH54.00-P-0010-01A
6	Remove ground line(s) for battery (batteries)	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.	AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
7	Secure vehicle on vehicle lift		AR00.60-P-0100SX
8	Remove air filter housing		AR09.10-P-1150SX
9	Suction refrigerant out of air conditioning	Vehicles with engine 272.974 and engine 273	AR83.30-P-1760SX
10	Detach engine wiring harness		AR01.00-P-2410SX
11	Detach purge line (4) from vacuum line (5)
12.1	Detach vacuum line (6) on resonance intake manifold	Except model 221.095/195
12.2	Remove vacuum line (6) to connecting point for brake booster	Model 221.095/195
13	Use service valve to reduce fuel pressure on fuel distributor rail (9)		AR07.03-P-1460-01VA
			Fig 12
		Engine 272	*BA07.03-P-1004-01B
14	Remove fuel feed line (8) from fuel distributor rail (9)	Seal connections with plugs.
			*BA07.03-P-1001-01B
			Fig 8
15.1	Empty expansion reservoir (10a) of power steering	Vehicles with AIRmatic without electrohydraulic power steering (EHPS) In the case of vehicles with AIRmatic the expansion reservoir is located directly on the power steering pump.
			Fig 10
15.2	Empty expansion reservoir for power steering (EHPS)	Vehicles with AIRmatic and EHPS For vehicles with AIRmatic and EHPS the expansion reservoir is located on the right side of vehicle directly behind the lamp unit.
			Fig 10
16	Empty expansion reservoir (10b) for the ABC system	Vehicles with code (487) Active Body Control (ABC)
			Fig 10
17.1	Detach return line (3b) from power steering expansion reservoir (10a)	Vehicles with AIRmatic without EHPS
17.2	Remove return line (3b) from expansion reservoir (10a) for power steering and from the fan shroud and lay return line (3b) on engine	Vehicles with AIRmatic and EHPS
18	Open clamp (12a) and detach oil line (14a) from power steering expansion reservoir (10a)	Vehicles with code (487) Active Body Control (ABC)
19	Open hose clamp (12b) and detach oil line (14b) from ABC system expansion reservoir (10b)	Vehicles with code (487) Active Body Control (ABC)
20	Open clamp (2) and detach hose (3a) from return line (3b)	Except model 221.095/195 Close off lines with stop plugs.
			Fig 8
21	Remove pressure line D1 from pressure line D2 for power steering and close off connectors with stop plugs	Model 221.095/195	AR46.25-P-3015SXH
			Fig 8
22	Remove nuts (1a) and remove return line (3b) from longitudinal member	Except model 221.095/195
23	Remove bolt (7a) and detach hydraulic line (17a) from valve unit (Y36/1)	Vehicles with code (487) Active Body Control (ABC) Close off hydraulic line with stop plugs.
			Fig 8
24	Remove bolts (15) and detach hydraulic line (17b) from front axle carrier (31)	Vehicles with code (487) Active Body Control (ABC)
25.1	Remove refrigerant line (20) to connecting point and condenser and close off connectors with stop plugs	Model 221 with engine 272
			Fig 8
25.2	Remove bolt (21) and detach refrigerant line (20) from refrigerant compressor (A9)	Model 221 with engine 273 Replace seal ring.
			*BA83.55-P-1003-01M
25.3	Disconnect refrigerant line (20) at separation point (20a) using a detaching tool	Model 216
			Figure
26	Remove nut (1b) and detach refrigerant line (16) from fluid reservoir (16a)	Engine 273 Replace seal ring.
			*BA83.55-P-1002-01M
27	Remove poly-V belt	Engine 272 except engine 272.974	AR13.20-P-0001SX
28	Detach refrigerant compressor (A9) and put it on the side with connected lines	Engine 272 except engine 272.974	AR83.55-P-5300SX
29	Drain coolant at radiator		AR20.00-P-1142SX
	Notes on coolant		AH20.00-N-2080-01A
30	Detach coolant line (32a) from valve (Y110)	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
31	Detach coolant line (32b) from coolant pump (34)	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
32	Remove coolant line (32c) from heating system shutoff valve	See "Disconnect Henn coupling".	AR09.41-P-1311-01AL
33	Disconnect coolant line from power electronics to expansion reservoir at the connecting point	Model 221.095/195
34	Disconnect coolant line from power electronics to DC/DC converter at connecting point	Model 221.095/195 The coolant line remains on the power electronics and on the front axle carrier.
35	Detach oil cooler lines from automatic transmission on radiator		AR27.55-P-0600SX
36	Remove catalytic converter or front exhaust system		AR49.10-P-7100SX
37	Loosen bolts (35) and remove cover panel (35a)
38	Remove bolt (36) and remove steering coupling (36a) from lower steering shaft		AR46.10-P-8000SX
39	Remove front wheels
	Remove/install wheels		AP40.10-P-4050SX
40	Remove tie rods from steering knuckles		AR46.40-P-0200SX
41	Remove strut rods from front axle carrier (31)		AR33.15-P-0160SX
42	Remove 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
43	Detach link rods from stabilizer bar	Vehicles with AIRmatic
			*BA32.20-P-1001-02O
44	Detach stabilizer bar from front axle carrier (31) and take to the rear	Vehicles with AIRmatic The suspension strut does not need to be removed from the spring control arm.
			*BA32.20-P-1003-02O
45	Remove brackets of rpm sensors on steering knuckles	Vehicles with code (487) Active Body Control (ABC)	AR42.30-P-0712SX
46	Unscrew nuts (37a) and loosen nuts (37b)	Vehicles with code (487) Active Body Control (ABC) Nuts (37b) must be loosened so that the suspension struts can move.
			*BA32.25-P-1001-04L
47	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 pallet forklift
48	Remove rear engine crossmember (23) with the rear engine mount		AR22.10-P-1180SX
49	Detach propeller shaft (22) from transmission output flange	Introduce colored identification of propeller shaft position relative to transmission output flange in order when installing to reproduce installation position created by at plant as otherwise drive line vibrations can occur.	AR41.10-P-0050-02SX
		Mount propeller shaft on transmission output flange.	AR41.10-P-0050-07SX
			*BA41.10-P-1001-01H
50	Remove bolts (31a) of longitudinal members	Install new bolts.
			*BA33.10-P-1001-01K
51	Lower engine transmission unit with front axle carrier (31)
52	Install in the reverse order
53	Perform wheel alignment check		AR40.20-P-0200SX
	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
54	Carry out engine test run and check engine for proper operation and leaks

Number	Designation			Engine 272	Engine 273
BA07.03-P-1001-01B	Union nut, fuel line to fuel distributor		Nm	20	20
BA07.03-P-1004-01B	Protective cap on service valve	Plastic	Nm	2	-
		Metal	Nm	15	-

Number	Designation			Model 216 without 4MATIC	Model 221 with code Z07/Z07+Z19
BA32.25-P-1001-04L	Nut, front suspension strut to front end	Stage 1	Nm	35	30
		Stage 2	Nm	-	35

Number	Designation			Model 221 with code 487 (ABC)	Model 221 without 4MATIC and except code 487, Z07/Z07+Z19
BA32.25-P-1001-04L	Nut, front suspension strut to front end	Stage 1	Nm	35	30
		Stage 2	Nm	-	-

Number	Designation		Model 221
BA32.20-P-1001-02O	Nut, link rod to stabilizer bar	Nm	90
BA32.20-P-1003-02O	Bolt, torsion bar to front axle carrier	Nm	50

Number	Designation		Model 216	Model 221
BA33.10-P-1001-01K	Bolt, front axle carrier to longitudinal member	Nm	180	180

Number	Designation		Engine 272	Engine 273
BA83.55-P-1002-01M	Nut connecting refrigerant line to air conditioning fluid reservoir	Nm	8	8
BA83.55-P-1003-01M	Bolt, refrigerant line to refrigerant compressor	Nm	20	20

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