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Remove/install intelligent servo module - AR27.19-P-0550EW

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TRANSMISSION 722.9 in MODEL 212, 218 

Fig 1: Intelligent Servo Module Components - Model 212, 218 (1 Of 2)
G09975724Courtesy of MERCEDES-BENZ USA
Fig 2: Intelligent Servo Module Components - Model 212, 218 (2 Of 2)
G07471866Courtesy of MERCEDES-BENZ USA
REMOVINGINSTALLING Remove/install     
DANGER 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
NOTES Information on preventing damage to electronic components due to electrostatic discharge   AH54.00-P-0001-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Release parking brake    
2 Disconnect battery ground line   AR54.10-P-0003EW
3.1 Remove engine compartment paneling TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212 with ENGINE 274
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278		  
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278		 AR61.20-P-1105EW
3.2 Remove bottom sections of soundproofing MODEL 212, 218 with ENGINE 642 with TRANSMISSION 722.9
MODEL 212, 218 with ENGINE 651 with TRANSMISSION 722.9		  
AR94.30-P-5300EW
4 Support and secure transmission (1) NOTES Secure transmission (1) with tensioning strap. Otherwise the transmission (1) may be damaged by it slipping off or tilting over.  
5 Remove rear engine cross member (2) TRANSMISSION 722.9 in MODEL 212, 218  
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212 with ENGINE 273
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651		 AR22.10-P-1180CW
TRANSMISSION 722.9 in MODEL 212 with ENGINE 156 AR22.10-P-1180CMG
6 Mark position of front flexible coupling relative to output flange and propeller shaft NOTES The marking is necessary to ensure that the factory installation position can be restored again when installed.
Otherwise the drive line may suffer from vibrations.		  
7 Mark vibration damper TRANSMISSION 722.9 in MODEL 212 with ENGINE 272.983
IMPORTANT Attach colored identification of vibration damper position relative to flexible coupling and propeller shaft, to enable the ex-factory installation position to be restored again during installation.		  
8 Detach drive shaft at transmission (1)   AR41.10-P-0050EW
9 Remove exhaust bracket (6) from transmission (1) TORQUE SPECIFICATION
TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651
TRANSMISSION 722.9 in MODEL 212.090		 *BA49.10-P-1023-01AE 
TORQUE SPECIFICATION
TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651
TRANSMISSION 722.9 in MODEL 212.090		 *BA49.10-P-1024-01AE 
10 Detach EGR lines from catalytic converters TRANSMISSION 722.9 in MODEL 212 with ENGINE 272.983  
AR14.20-P-1020-01EWD
TORQUE SPECIFICATION
TRANSMISSION 722.9 in MODEL 212 with ENGINE 156
TRANSMISSION 722.9 in MODEL 212 with ENGINE 272
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 157
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 276
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 278
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642
TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 651
TRANSMISSION 722.9 in MODEL 212.090		 *BA49.10-P-1041-01AE 
11 Detach catalytic converters from exhaust manifolds Engine 272, 273, 276, 278  
TORQUE SPECIFICATION Bolt, catalytic converter to exhaust manifold *BA49.10-P-1001-01AE 
12 Remove front exhaust pipe from diesel particulate filter TRANSMISSION 722.9 in MODEL 212, 218 with ENGINE 642  
TORQUE SPECIFICATION Bolt, pipe clamp to diesel particulate filter *BA49.10-P-1020-01AE 
13 Detach electrical connector from Intelligent servo module for DIRECT SELECT (A80)    
14 Lower transmission (1) slightly NOTES When being lowered the engine must not rest on the front axle carrier.
Damage could occur on the engine oil pan otherwise.		  
15 Remove bolts (10) from intelligent servo module for DIRECT SELECT (A80). INSTALLATION IMPORTANT Replace bolts (10).  
TORQUE SPECIFICATION Standard bolt/hexagon-spacer bolt, shift module (ISM) to transmission housing *BA27.40-P-1021-01A 
16 Remove intelligent servo module for DIRECT SELECT (A80) with bleed hose NOTES When reusing the intelligent servo module for DIRECT SELECT (A80) do not detach the vent hose.
Otherwise there may be leakages in the connecting points, with resulting water entry.
INSTALLATION IMPORTANT When replacing the intelligent servo module for DIRECT SELECT (A80), the vent hose must be replaced.
The positions of the range selector shaft (3) and the intelligent servo module for DIRECT SELECT (A80) must line up. If necessary, the range selector shaft (3) can be rotated accordingly when reusing the removed intelligent servo module for DIRECT SELECT (A80).		  
SPECIAL TOOL Assembly tool Fig 3
17 Rotate range selector shaft (3) of transmission (1) in counterclockwise direction up to the end stop at position "D" (arrow) When replacing the intelligent servo module for DIRECT SELECT (A80).
IMPORTANT New intelligent servo module for DIRECT SELECT (A80) set to position "D" (arrow) (condition as supplied).		  
18 Install in the reverse order    
19 Connect Star Diagnosis, read out fault memory and conduct initial startup of the intelligent servo module for DIRECT SELECT (A80) After replacing the intelligent servo module for DIRECT SELECT (A80).  
REFER TO SELF-DIAGNOSTIC SYSTEMS AD00.00-P-2000-04A
TRANSMISSION HOUSING

Number Designation TRANSMISSION 722.9
BA27.40-P-1021-01A Standard bolt/hexagon-spacer bolt, shift module (ISM) to transmission housing Stage 1 Nm 4
Stage 2 ∠° 90
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1001-01AE Bolt, catalytic converter to exhaust manifold Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1020-01AE Bolt, pipe clamp to diesel particulate filter Nm 35 35
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1023-01AE Bolt, exhaust system bracket to transmission Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1023-01AE Bolt, exhaust system bracket to transmission Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1024-01AE Bolt/nut, exhaust system bracket to exhaust system Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1024-01AE Bolt/nut, exhaust system bracket to exhaust system Nm 20 20
EXHAUST SYSTEM

Number Designation ENGINE 156, 157, 271, 272, 273, 276, 278 in MODEL 212 ENGINE 157, 276, 278 in MODEL 218
BA49.10-P-1041-01AE Bolt, clamp for exhaust gas recirculation line to catalytic converter Nm 9 9
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 212 ENGINE 642, 651 in MODEL 218
BA49.10-P-1041-01AE Bolt, clamp for exhaust gas recirculation line to catalytic converter Nm - -
Fig 3: Identifying Assembly Tool (722 589 03 09 00)
G09975726Courtesy of MERCEDES-BENZ USA
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