Remove/install engine - AR01.10-P-2400SYZ

ENGINES 642 in MODEL 221.08/18 

Shown on a vehicle without an electrohydraulic steering system (EHPS) 

Fig 1: Identifying Engine Remove/Install Components - Shown On Vehicle Without Electrohydraulic Steering System (EHPS)

Courtesy of MERCEDES-BENZ USA

Fig 2: Identifying Engine Remove/Install Components - Shown On Vehicle Without EHPS

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Shown on a vehicle without EHPS 

Shown on engine 642.9 

Fig 3: Identifying Engine Remove/Install Components - Shown On Engine 642.9

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Engine Remove/Install Components (1 Of 3)

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Fig 5: Identifying Engine Remove/Install Components (2 Of 3)

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Fig 6: Identifying Engine Remove/Install Components (3 Of 3)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	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 moving off. Wear closed and close-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
	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  to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning  caused by swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
	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 pour liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
	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
		Only tighten bolts and nuts of the chassis components in the curb condition.
	Notes on coolant		AH20.00-N-2080-01A
	Notes on battery		AH54.10-P-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on AIRmatic		AH32.22-P-1000-02SX
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
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
5	Disconnect battery ground line		AR54.10-P-0003SX
6	Secure vehicle on vehicle lift		AR00.60-P-0100SX
7	Remove bottom sections of soundproofing		AR61.20-P-1105SX
8	Remove engine trim panel		AR01.10-P-2405SXI
9	Remove impact plate	Engine 642.8 The impact plate is installed before the belt drive.
10	Drain air conditioning system		AR83.30-P-1760SX
11	Remove injection system control unit and expose engine wiring harness		AR07.08-P-7008SXI
12	Detach vacuum line (2) from vacuum pump	Unclip vacuum line (2) from guides and lay to the side in engine compartment.
13	Remove both engine air intake ducts from air filter
14	Remove heat shield (3) and shield over the turbocharger
15	Disconnect electrical connector on switchable engine mount, unclip electrical line from brackets and set aside	Vehicles with a switchable engine mount
16	Extract oil from power steering expansion reservoir	For vehicles with EHPS the expansion reservoir is located on the right side of vehicle directly behind the lamp unit. For vehicles without EHPS the expansion reservoir is located on the power steering pump on the left side of vehicle.
			Fig 7
17.1	Remove return hose from expansion reservoir for P/S	Vehicles with EHPS Seal the connections.	AR46.25-P-3015SXH
			Fig 8
17.2	Disconnect hydraulic line for the P/S cooler at the connecting points	Vehicles without EHPS Seal the connections.	AR46.25-P-3015SXC
			Fig 8
18	Disconnect pressure line D1 from pressure line D2 at connecting point	Vehicles with EHPS Slide tool in and with chamfered area into the connecting point up to end stop, to avoid damage to the rubber boot. Collect oil which runs out and seal connections immediately.	AR46.25-P-3015SXH
19	Detach bracket for the P/S pipework on left longitudinal member and disconnect the hose connection	Engine 642.9
20	Drain coolant at radiator		AR20.00-P-1142SXI
21	Detach coolant hose (4) on thermostat housing	In order to avoid leaks on the engine, check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease and ensure exact seating of detent springs: ↓
		Open and close coupling.	AR09.41-P-1311-01AL
22	Detach return line (7) from thermostat housing	Check hose clamp, install new part if necessary.
23	Detach coolant hose (11) on fitting (10)	In order to avoid leaks on the engine, check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease and ensure exact seating of detent springs: ↓
		Open and close coupling.	AR09.41-P-1311-01AL
24	Remove coolant hose (13) from circulation pump at fitting (10)	Check hose clamp for tight seating; replace if necessary.
25	Detach coolant hose (12) on exhaust gas recirculation housing	Check hose clamp for tight seating; replace if necessary.
26	Unclip charge air hose on engine charge air duct downstream of charge air cooler	In order to avoid leaks on the engine, check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease and ensure exact seating of detent springs: ↓
		Open and close coupling.	AR09.41-P-1311-01AL
27	Remove pressure differential sensor (DPF)		AR07.04-P-0012SXI
28	Remove shield on AT and disconnect from the underlying electrical connector		AR27.40-P-0700-01SX
			*BA27.40-P-1014-01A
			*BA27.40-P-1019-01A
29	Disconnect electrical connector on intelligent servo module for DIRECT SELECT (A80) and lay transmission wiring harness outside the working area
30	Remove screw (9)
31	Remove oil cooling lines for the AT on cooler	Seal the connections.	AR27.55-P-0600SYZ
			Fig 8
32	Remove fuel lines (6) at fuel pipes	Seal the connections. Replace hose clamps.
			Fig 8
33	Drain engine oil	Replace sealing ring of oil drain screw.
	Engine oil and filter change		AP18.00-P-0101SXI
34	Detach refrigerant line (16) at condenser (16)	To do this, unscrew nut (1b).
35	Detach clamp (8) on exhaust pipe or SCR catalytic converter and disconnect exhaust pipe from diesel particulate filter	Tie up exhaust pipe to avoid damaging exhaust pipe.
			*BA49.10-P-1009-01V
			*BA49.10-P-1012-01V
36	Detach propeller shaft (22) on AT		AR41.10-P-0050-02SX
		Mount propeller shaft (22) on AT.	AR41.10-P-0050-07SX
			*BA41.10-P-1001-01H
37	Remove the front wheels		AP40.10-P-4050SX
38	Detach steering coupling from rack-and-pinion steering		AR46.10-P-8000SX
39	Detach bracket and rpm sensor from steering knuckles and fasten unstressed		AR42.30-P-0712SX
40	Detach brake caliper with attached brake hoses from steering knuckles	Fasten brake caliper attached brake hose using hooks onto the vehicle. Create access to brake hose and electrical line from the guides as required. The brake hose must not subjected to tension or be kinked otherwise it will be damaged.	AR42.10-P-0070SX
41	Expose electrical line for the level sensor at the front left and front right and disconnect the electrical connector
42	Detach suspension struts from spring control arms		AR32.25-P-1017SYZ
43	Detach upper ball joint for the upper transverse control arm from steering knuckles	Secure steering knuckle to prevent it from tipping over.	AR33.20-P-0500SX
44	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	Major assembly lifting platform/scissors-type pallet forklift Ensure even alignment of support plates.	AR01.10-P-2500-01A
45	Remove rear engine crossmember	To do this, remove bolts (23a) of rear engine crossmember (23) The rear engine crossmember (23) remains on the transmission.	AR22.10-P-1180SW
46	Remove bolts (31a) of longitudinal members	Replace bolts (31a).	AR33.10-P-0100SYZ
47	Lower engine transmission unit with front axle carrier (31)	Ensure that engine does not hit up against components during removal and installation to avoid damage to engine or other components.
48	Install in the reverse order
49	Fill power steering pump and bleed		AR46.30-P-0010SX
50	Bleed cooling system		AR20.00-P-1142-06SXI
51	Check cooling system for leaktightness and correct if necessary		AR20.00-P-1010SX
52	Check engine oil level; correct if necessary		AR18.00-P-3035-01SXI
		Engine 642 with code (474) Particulate filter	*BF18.00-P-1001-01S
		Engine 642 except code (474) Particulate filter	*BF18.00-P-1001-01A
53	Check transmission oil level and correct if necessary		AR27.00-P-0270SYZ
54	Check for leaks with engine running
55	Read out fault memory	Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
56	Perform wheel alignment check		AR40.20-P-0200SX

Fig 7: Identifying Hand Pump (210 589 00 71 00)

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Fig 8: Identifying Set Of Stop Plugs (129 589 00 91 00)

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Fig 9: Identifying Holding Device (129 589 01 21 00)

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