Remove/Install Engine With Front Axle Carrier - AR01.10-P-2500MLJ
MODEL 166, 292 with ENGINE 157, 278
MODIFICATION NOTES
| 29.08.2017 | Sequence of operation steps revised. | Operation steps 1 to 6. | |
| 29.08.2017 | Instruction supplemented. | Operation step 3. | |
| 29.08.2017 | Document reference supplemented. | Operation steps 31, 36 and 37. | |
| 29.08.2017 | Special tools supplemented. | Operation steps 17, 25 and 31. |
Shown on model 166
Shown on model 166 with engine 157
Shown on model 166
| Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil | Wear protective gloves, protective clothing and safety glasses. Do not fill engine oil into beverage containers. |
AS18.00-Z-0001-01A | |
| Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. | AS00.00-Z-0013-01A | |
| Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A | |
| Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Risk of injury . Skin or eye injuries may result when handling hot or glowing objects. | Wear protective gloves, protective clothing and safety glasses, if necessary. | AS00.00-Z-0002-01A | |
| Risk of injury to skin and eyes due to handling of transmission oil. Health risk caused by swallowing transmission oil | Wear protective gloves, protective clothing and safety glasses. Do not pour transmission oil into beverage bottles. |
AS00.40-Z-0001-01A | |
| Risk of injury caused by scraping or cutting body parts on sharp vehicle parts | Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. | AS00.00-Z-0017-01A | |
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Information on preventing damage to electronic components due to electrostatic discharge | AH54.00-P-0001-01A | ||
| Notes on avoiding damage through contamination and foreign objects | AH00.00-P-5000-01A | ||
| Topical note | Notes on coolant | AH20.00-N-2080-01A | |
| Topical note | Notes on active roll stabilization | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
AH32.34-P-0001-01A |
| Note on calculation of tightening torque when using insertion or socket tools with various effective lengths | AH00.00-P-0015-01CW | ||
| Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases | AH01.10-P-0001-01A | ||
| General information on work on gasoline direct injection system | AH07.00-P-2000-01A | ||
| Notes on AIRmatic | Model 166, 292 with engine 157, 278 with code 489 (AIRMATIC) | AH32.22-P-1000-02GZ | |
| Remove/install | |||
| 1 | Deactivate easy entry/exit feature | Model 166, 292 with engine 157, 278 with code 275 (Memory package) |
|
| 2 | Turn front wheels to straight-ahead position and fix steering wheel in place with holding device | Figure | |
| 3 | Secure vehicle against rolling away, shift transmission to neutral position and release parking brake | ||
| 4 | Secure vehicle on vehicle lift | AR00.60-P-0100GZ | |
| 5 |
Relieve all pressure in front suspension struts with diagnostic system | Model 166, 292 with engine 157, 278 with code 489 (AIRMATIC) |
AD00.00-P-2000-04A |
| 6 | Disconnect battery ground line | AR54.10-P-0003GZ | |
| 7 | Remove upper engine covers | ||
| 8 | Remove engine compartment paneling | AR61.30-P-1001GQ | |
| 9 | Remove right and left part of firewall | ||
| 10 | Drain off coolant | Drain coolant from low-temperature circuit | AR09.41-P-6834MLJ |
| Drain off coolant | AR20.00-P-1142GQ | ||
| 11 | Remove fan unit | AR20.40-P-5050MLJ | |
| 12 | Remove right air inlet box upper section (6) on the right | AR82.30-P-6400GZ | |
| 13 | Pinch off engine wiring harness | AR01.00-P-2410-02MLJ | |
| *BA54.10-P-1002-01C | |||
| 14 | Remove coolant hose (21) at switchover valve (22) of stationary heater and unclip at longitudinal member | Model 166, 292 with engine 157, 278 with code 228 (Auxiliary heater) |
Figure |
| 15 | Remove coolant line (45) from thermostat housing | AR20.20-P-7441-01RQ | |
| 16 | Remove coolant hose from heat exchanger at partition | Figure | |
| 17 | Release and disconnect bleed line (13) at separating point | AR20.20-P-7441-01RQ | |
| 18 | Remove coolant hose (15) at oil filter housing | Figure | |
| 19 | Remove coolant line (14) at expansion reservoir | Figure | |
| 20 | Remove coolant hose (10) | Figure | |
| 21 | Remove coolant hose (18) at additional radiator in wheel arch | AR20.20-P-7441-01RQ | |
| 22 | Remove coolant hose at coolant line (11) | AR20.20-P-7441-01RQ | |
| 23 | Remove coolant line (12) at cooler | AR20.20-P-7441-01RQ | |
| 24 | Remove lines (19) from additional oil cooler | Model 166, 292 with engine 157 |
AR20.20-P-7441-01RQ |
| *BA18.30-P-1004-01G | |||
| 25 | Release and disconnect purge line (5), place to one side and seal openings with suitable stop plugs | Figure | |
| 26 | Remove vacuum line (4) at brake booster | Model 166, 292 with engine 157, 278 Model 166, 292 with engine 278 |
AR43.10-P-0355GQ |
| 27 | Remove engine management control unit | AR07.08-P-7008MLJ | |
| 28 | Suction off hydraulic fluid from expansion reservoir for Active Roll Stabilization | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
Fig 1 |
| 29 | Remove hose from oil line (17) | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
Figure |
| 30 | Remove ground line at refrigerant compressor | AR83.55-P-5300GQ | |
| 31 | Remove refrigerant lines at condenser and at engine compartment separating point and seal openings with suitable stop plugs | AR83.30-P-6540GQ | |
| Compressor oils (specification 362.1) | Use new sealing rings. Wet all threads and sealing rings with compressor oil. Refrigerant can otherwise escape. |
BB00.40-P-0362-01A | |
| *BA83.30-P-1009-01J | |||
| Figure | |||
| 32 | Remove steering coupling (3) | Do not turn steering wheel when steering coupling (3) is removed. Otherwise the clock spring contact will be destroyed. |
AR46.10-P-8000GQ |
| 33 | Remove bleed line of front axle differential at heat shield | ||
| 34 | Remove front sections for front fender liner (20) | AR88.10-P-1310GQ | |
| 35 | Remove underfloor panelings (36, 44) | AR61.30-P-1001GQ | |
| 36 | Disconnect high-pressure line (32) at separating point, remove frame floor assembly and seal openings with suitable stop plugs | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
AR32.00-P-0001-01A |
| Figure | |||
| Figure | |||
| Figure | |||
| 37 | Disconnect low-pressure line (31) at connecting point and close off openings with stop plugs | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
AR32.00-P-0001-01A |
| Figure | |||
| Figure | |||
| Figure | |||
| 38 | Remove oil lines (23, 25) of transmission at thermostat (24) | Model 166 with engine 278 with transmission 722.9 Model 166, 292 with engine 157 with transmission 722.9 Model 292 with engine 278 with transmission 725.0 |
AR27.55-P-0600GQ |
| 39 | Remove air duct segments for engine mount cooling (16) on left and right at cooler | ||
| 40 | Unclip brake lines at left and right steering knuckle (29) | ||
| 41 | Remove electric line for brake pad contact sensor at right brake caliper and unclip at right steering knuckle (29) and place to one side | ||
| 42 | Remove left and right brake caliper (28) at steering knuckles (29) and secure against falling down | AR42.10-P-0070GZ | |
| 43 | Remove rpm sensors at steering knuckles (29), unclip from bracket and place to one side | AR42.30-P-0712GZ | |
| 44 | Remove upper transverse control arms at steering knuckles (29) | AR33.25-P-0400GZ | |
| 45 | Remove suspension struts at lower control arms (30) | AR32.25-P-1017GQ | |
| 46 | Remove heat shield (40) at transfer case (39) | Model 166 with engine 157, 278 with transmission all with code 430 (On & off-road package) Model 292 with engine 157 with transmission 722.90 with code 430 (On & off-road package) Model 292 with engine 278 with transmission 725.0 with code 430 (On & off-road package) |
AR28.10-P-0100GQ |
| 47 | Release and disconnect electrical connectors at transfer case (39) | Model 166 with engine 157, 278 with transmission all with code 430 (On & off-road package) Model 292 with engine 157 with transmission 722.90 with code 430 (On & off-road package) Model 292 with engine 278 with transmission 725.0 with code 430 (On & off-road package) |
AR28.10-P-0100GQ |
| 48 | Remove propeller shaft (41) at transmission output flange of transfer case (39) | Tightening procedure for rear propeller shaft to transfer case | AR41.10-P-0050-17GZ |
| Topical note | Notes on threaded connections fastened using a tightening angle-based tightening process | AH00.00-P-0020-01A | |
| *BA41.10-P-1001-01F | |||
| Fig 3 | |||
| 49 | Remove left and right catalytic converters (38) | AR49.10-P-5500MLJ | |
| 50 | Remove screws of stiffening plates (33) at longitudinal members | *BA33.10-P-1002-01I | |
| 51 | Remove stiffening plates (37, 43) | If installed. |
*BA33.10-P-1003-01I |
| 52 | Relieve fuel pressure over diagnostic socket | AR07.03-P-1460-01VA | |
| *BA07.03-P-1007-01E | |||
| Figure | |||
| 53 | Detach fuel line at diagnostic socket and close off openings with suitable stop plugs | *BA07.03-P-1008-01E | |
| Figure | |||
| 54 | Support front axle carrier (26) with lifting platform and mounting plates and secure entire engine-transmission unit with suitable means against slipping and falling down | ||
| 000 588 03 62 00 Lifting platform | WS01.00-P-0091A | ||
| 55 | Remove rear engine crossmember (35) with the rear engine mount | AR22.10-P-1180GQ | |
| 56 | Remove screws (27) of front axle carrier (26) from longitudinal members | AR33.10-P-0100GQ | |
| Topical note | Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | |
| 57 | Lower engine transmission unit and front axle carrier (26) | ||
| 000 588 03 62 00 Lifting platform | Do not crush or kink or subject lines to tension. Engine-transmission unit may not be in contact with body. Otherwise damage can occur to lines and detachable parts. |
WS01.00-P-0091A | |
| 58 | Install in the reverse order | ||
| Concluding tasks | |||
| 59 | Fill and bleed ACTIVE CURVE SYSTEM | Model 166, 292 with engine 157, 278 with code 468 (ACTIVE CURVE SYSTEM) |
AR32.34-P-0021GQ |
| 60 | Check engine oil level and correct | ||
| AP18.00-P-1811MP | |||
| 61 | Check transmission oil level and correct if necessary | Model 166 with engine 278 with transmission 722.9 Model 166, 292 with engine 157 with transmission 722.9 |
AR27.00-P-0270W |
| Model 166, 292 with engine 278 with transmission 725.0 up to model year 2015 |
AR27.00-P-0270EWM | ||
| Model 166, 292 with engine 278 with transmission 725.0 as of model year 2015 |
AR27.00-P-0270EWN | ||
| Risk of burn injuries , suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. | Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area. | AS49.00-Z-0001-01A | |
| Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | AS00.00-Z-0005-01A | |
| 62 | Perform engine test run; as part of this check engine, transmission and radiator package for proper operation and leak tightness |
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 157 | Engine 278 | ||
|---|---|---|---|---|---|
| BA07.03-P-1007-01E | Protective cap on service valve | Plastic | Nm | 2 | 2 |
| Metal | Nm | 15 | 15 | ||
INJECTION NOZZLES, INJECTION VALVES, LINES
| Number | Designation | Engine 157 | Engine 278 | |
|---|---|---|---|---|
| BA07.03-P-1008-01E | Fuel line union nut on service valve | Nm | 24 | 24 |
OIL COOLING SYSTEM
| Number | Designation | Engine 157 | |
|---|---|---|---|
| BA18.30-P-1004-01G | Bolt, oil cooler line to oil cooler | Nm | 9 |
FRONT AXLE CARRIER
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA33.10-P-1002-01I | Bolt, stiffening plate to longitudinal member | M10 | Nm | 60 | 60 |
FRONT AXLE CARRIER
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA33.10-P-1003-01I | Bolt, stiffening plate to body | M8 | Nm | 20 | 20 |
PROPELLER SHAFT
| Number | Designation | Model 166 | Model 292 | ||
|---|---|---|---|---|---|
| BA41.10-P-1001-01F | Self-locking screw/bolt of propeller shaft at transfer case/adapter housing (to rear axle) | Stage 1 | Nm | 40 | 40 |
| Stage 2 | ∠° | 90 | 90 | ||
BATTERY
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA54.10-P-1002-01C | Nut, circuit 30 in prefuse box | Nm | 15 | 15 |
AIR CONDITIONING
| Number | Designation | Model 166 | Model 292 | |
|---|---|---|---|---|
| BA83.30-P-1009-01J | Nut, high-pressure line to condenser/engine compartment connecting point/expansion valve | Nm | 8 | 8 |