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

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ENGINE 157, 278 in MODEL 212, 218

ENGINE 276.9 in MODEL 212.08/28

ENGINE 278 in MODEL 207

MODIFICATION NOTES

24.9.14

Union nut fuel line to the fuel rail

BA07.03-P-1001-01D

Shown on model 212.073

Fig 1: Engine With Front Axle Carrier Remove/Install Components - Shown On Model 212.073 (1 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 2: Engine With Front Axle Carrier Remove/Install Components - Shown On Model 212.073 (2 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 3: Engine With Front Axle Carrier Remove/Install Components - Shown On Model 212.073 (3 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 4: Engine With Front Axle Carrier Remove/Install Components - Shown On Model 212.073 (4 Of 4)

Courtesy of MERCEDES-BENZ USA

Shown on model 207 with code (139) Measures for engine cooling M157/M278

Fig 5: Engine With Front Axle Carrier Remove/Install Components - Shown On Model 207 With Code (139)

Courtesy of MERCEDES-BENZ USA

	Remove/install
	Notes on repair work on suspension components		AH00.00-P-0100-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Notes on AIRmatic		AH32.22-P-1000-02EW
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Relieve pressure in front suspension struts to zero using STAR DIAGNOSIS
		Vehicles with code 489 (AIRMATIC (air suspension with continuous adjustment damping))	AD00.00-P-2000-04A
2	Deactivate easy entry/exit function	Vehicles with code 275 (Memory package for electrically adjustable front seats)
3	Turn front wheels to straight-ahead position and secure steering wheel with holding device	The steering wheel must not be turned when detaching steering coupling. The clock spring contact will be destroyed otherwise.
3		Retainer device	Figure
4	Set DIRECT SELECT gear selector switch to position "N" and release parking brake
5	Detach ground line from battery		AR54.10-P-0003EW
	Notes on battery		AH54.10-P-0001-01A
6	Secure vehicle on vehicle lift	MODEL 207	AR00.60-P-0100CW
6	Secure vehicle on vehicle lift	MODEL 212, 218	AR00.60-P-0100EWS
7	Remove bottom engine compartment paneling		AR61.20-P-1105EW
8	Drain coolant	MODEL 207	AR20.00-P-1142FH
	Notes on coolant		AH20.00-N-2080-01A
	Notes on coolant	MODEL 212, 218	AR20.00-P-1142EL
9.1	Remove upper engine cover (2) completely	Engine 157, 278
9.2	Remove front section of the upper engine cover	ENGINE 276.9
10	Drain coolant in low-temperature circuit	Vehicles with code (139) Measures for engine cooling M157/M278 The coolant drain screw for the low-temperature circuit is located in the low-temperature circuit hose package at the front right in engine compartment. The low-temperature circuit coolant expansion reservoir (40) is located under the center engine cover.
	Notes on coolant		AH20.00-N-2080-01A
11.1	Remove both engine air intake ducts (3) upstream of the air filter housings (4)	Engine 157, 278
11.2	Remove engine air intake duct upstream of air filter housings	ENGINE 276.9
12.1	Remove both air filter housings (4)	Engine 157, 278
12.2	Remove air filter housing	ENGINE 276.9
		Bolt, air filter to air intake pipe support brace	*BA09.10-P-1002-01M
		Bolt, air filter to cylinder head cover	*BA09.10-P-1001-01M
13	Suction refrigerant out of air conditioning		AR83.30-P-1760CW
14	Disconnect refrigerant line (6) at upper connecting point on engine compartment	Seal openings using stop plugs.
14		Record plug	Figure
15	Detach purging line (11) on purge switchover valve (Y58/1)
16	Detach vacuum line (14) on bulkhead (7) connecting point and place to one side
17	Detach coolant hose (12) on heater shutoff valve (10) and bulkhead (7) and remove upwards
18	Disconnect bleed line (19) at connecting point	Engine 157, 278
19	Disconnect coolant hose (42) from coolant line (41) to the low-temperature circuit coolant expansion reservoir (40)	Vehicles with code (139) Measures for engine cooling M157/M278
20	Disconnect coolant line (43) from distributor below the high-temperature circuit coolant expansion reservoir (45)	Vehicles with code (139) Measures for engine cooling M157/M278
			AR09.41-P-1311-01AL
		See "Disconnect Henn coupling".
21	Detach coolant hose (44) on the coolant circulation pump (M13/5)	Vehicles with code (139) Measures for engine cooling M157/M278
22	Detach coolant hose (13) on coolant pump and cooler (21)		AR09.41-P-1311-01AL
22	Detach coolant hose (13) on coolant pump and cooler (21)	See "Disconnect Henn coupling". Place coolant hose (13) to one side.	AR09.41-P-1311-01AL
23	Detach coolant hoses (15, 16) at coolant lines for charge air cooler	Engine 157, 278
24	Detach coolant hose (17) at thermostat housing and cooler (21) and remove	Engine 157, 278	AR09.41-P-1311-01AL
25	Remove cold air intake (22)
26	Fasten cooler (21) to upper radiator crossmember (23) and secure against falling down
27	Disconnect engine wiring harness on the vehicle side	Engine 157, 278	AR01.00-P-2410-02ELB
27	Disconnect engine wiring harness on the vehicle side	ENGINE 276.9	AR01.00-P-2410-02EL
28	Detach front wheels
		MODEL 207	AP40.10-P-4050CW
		MODEL 212, 218	AP40.10-P-4050EW
29	Detach link rods (24) from torsion bar (25)	MODEL 207	AR32.20-P-0300CW
29	Detach link rods (24) from torsion bar (25)	MODEL 212, 218 The torsion bar (25) remains on the front axle carrier (31).	AR32.20-P-0300EW
30	Remove brake caliper (26) from steering knuckles and fasten with attached lines to suspension strut (27)	ENGINE 276.9 in MODEL 218	AR42.10-P-0070EL
		ENGINE 157 in MODEL 212.074/075/076/274/275/276 with CODE B07 (Ceramic brake system) ENGINE 157 in MODEL 218.374/375/376/974/975/976 with CODE B07 (Ceramic brake system)	AR42.10-P-0225QQ
		ENGINE 276.9 in MODEL 212.08/28, 218 divided floating caliper brake ENGINE 278 in MODEL 207 divided floating caliper brake ENGINE 278 in MODEL 212, 218 divided floating caliper brake	AR42.10-P-0070EWC
		ENGINE 276.9 in MODEL 212.08/28 undivided 1-piston floating caliper brake ENGINE 278 in model 207 undivided 1-piston floating caliper brake ENGINE 278 in MODEL 212 undivided 1-piston floating caliper brake	AR42.10-P-0070EWB
		ENGINE 157, 278 in MODEL 212, 218 4-piston fixed-caliper brake ENGINE 276.9 in MODEL 212.08/28, 218 4-piston fixed-caliper brake	AR42.10-P-0070EWA
31.1	Detach electrical line to intelligent servo module for DIRECT SELECT (A80) and unclip on transmission (28)	Model 212, 218 with transmission 722.9
31.1		Model 212, 218 with transmission 722.9	AR27.19-P-0550EW
31.2	Detach shift rod on range selector lever from transmission (28)	Engine 278 in model 207 with transmission 722.9
			AR27.60-P-0985CW
		Replace safety clamp.
32	Disconnect electrical line on electrical transmission oil pump (M42) and unclip on transmission (28)	Model 207 with transmission 722.9	AR27.30-P-0651FH
32		Model 212, 218 with transmission 722.9 See "Remove auxiliary oil pump for AT (28)".	AR27.30-P-0651EL
33	Remove shield (29) and disconnect electrical connection for transmission control; lay wiring harness outside the working area	MODEL 207	AR27.40-P-0700-01CW
		MODEL 212, 218	AR27.40-P-0700-01EW
		Screw/bolt, heat shield to transmission housing	*BA27.40-P-1014-01A
34	Disconnect exhaust system at center muffler connecting point on rear muffler	MODEL 207	AR49.10-P-7100CW
34		MODEL 212, 218	AR49.10-P-7100EL
35	Remove steering coupling (30)	MODEL 207	AR46.10-P-8000CW
35	Remove steering coupling (30)	MODEL 212, 218	AR46.10-P-8000EW
36	Detach refrigerant line (39) at lower connecting point	Seal openings using stop plugs.
36	Detach refrigerant line (39) at lower connecting point	Record plug	Figure
37	Detach electrical line (32) at rack-and-pinion steering, unclip on front axle carrier (31) and set aside	ENGINE 278 in MODEL 207 without CODE 211 (Direct-Steer system)	AR46.20-P-0600CW
37		ENGINE 157, 278 in MODEL 212 with CODE 211 (Direct-Steer system) ENGINE 157, 278 in MODEL 218 ENGINE 276.9 in MODEL 212.08/28 with CODE 211 (Direct-Steer system) ENGINE 278 in MODEL 207 with CODE 211 (Direct-Steer system)	AR46.20-P-0600EL
38	Detach oil cooling lines (18) for transmission (28) at connecting point	Transmission 722.9	AR27.10-P-0501-03CW
		Seal openings using stop plugs.
		Record plug	Figure
39.1	Detach oil lines for engine oil cooling on oil cooler	Engine 157 in model 212, 218
		Seal openings using stop plugs.
		Record plug	Figure
39.2	Detach oil lines for engine oil cooling at connecting point to engine oil cooler	Vehicles with code (139) Measures for engine cooling M157/M278
			AR18.30-P-1000ELB
		Seal openings using stop plugs.
		Record plug	Figure
40	Disconnect electrical connection from rpm sensors, right front brake pad contact sensor and front axle damping valve unit connector on left and right		AR33.10-P-0100-06CW
40		Unclip electrical lines from brackets.
41	Detach suspension strut (27) from steering knuckle	MODEL 207	AR33.10-P-0200CW
41	Detach suspension strut (27) from steering knuckle	MODEL 212, 218	AR33.10-P-0200EW
42	Detach bracket (33) for front level sensor's link rod from cross strut (34)	Vehicles with code 489 (AIRmatic (air suspension with continuously adjustable damping) left and right. Vehicles with automatic headlamp range adjustment and without code 489 (AIRmatic (air suspension with continuously adjustable damping) left only. Do not unclip link rod from bracket (33). The link rod will be damaged otherwise. Replace cable tie.
43	Remove bracket (35) for the lower engine compartment paneling
44	Relieve fuel pressure through service valve		AR07.03-P-1460-01VA
		Engine 276	*BA07.03-P-1007-01D
		Engine 157, 278	*BA07.03-P-1007-01E
		Pressure hose	Figure
45	Detach fuel line (8) on fuel distributor (9)	Seal openings using stop plugs.
		Engine 276	*BA07.03-P-1001-01D
		Engine 157, 278	*BA07.03-P-1001-01E
		Record plug	Figure
46	Detach strut between RH and LH side of vehicle underbody	Bolt, rear reinforcement brace to frame floor assembly	*BA61.10-P-1003-01H
47	Remove diagonal strut (36) and supporting strut (37) for front axle carrier (31)	MODEL 207	AR33.10-P-0001CW
47		MODEL 212, 218	AR33.10-P-0001EW
48	Remove coolant line (20L, 20R) for engine mount
49	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	When doing so ensure that mounting plates are correctly aligned. Major assembly lifting platform/scissors trolley jack
50	Remove rear engine crossmember with rear engine mount		AR22.10-P-1180CW
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
51	Detach drive shaft from transmission output flange/transfer case	MODEL 207	AR41.10-P-0050CW
51		MODEL 212, 218 Apply color markings to the transmission to indicate position of the propeller shaft relative to the transmission output flange. This ensures that the components are reinstalled at the factory installation position. Otherwise, drivetrain vibrations will occur.	AR41.10-P-0050EW
52	Unscrew screw/bolts (31a) on front axle carrier (31) from longitudinal members	MODEL 207	AR33.10-P-0001CW
52		MODEL 212, 218 The screw/bolts (31a) are self-tapping, therefore pay attention to the following points: Never recut thread in longitudinal member, replace screw/bolts (31a), only use original screw/bolts (4 pieces), do not position screw/bolts (31) at an angle when screwing in, do not use an impact wrench/driver, observe tightening torque.	AR33.10-P-0001EW
53	Lower engine transmission unit with front axle carrier (31)	Ensure that engine does not touch any body panels or major assemblies and that no lines are pinched or damaged.
54	Install in the reverse order
55	Check cooling system for leaktightness	MODEL 207	AR20.00-P-1010FH
55	Check cooling system for leaktightness	MODEL 212, 218	AR20.00-P-1010EL
56	Check low-temperature circuit cooling system for leaktightness	Vehicles with code (139) Measures for engine cooling M157/M278
		MODEL 207	AR20.00-P-1010FH
		MODEL 212, 218 Attach tester cap on low-temperature circuit coolant expansion reservoir and apply test pressure to low-temperature circuit.	AR20.00-P-1010EL
57	Correct transmission oil level	Transmission 722.9 except transmission 722.96	AR27.00-P-0270W
57	Correct transmission oil level	Transmission 722.96	AR27.00-P-0270SYZ
58	Perform wheel alignment check		AR40.20-P-0200EW
59	Read out fault memory with STAR DIAGNOSIS and delete if necessary
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
	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
60	Carry out an engine test run, checking the engine for proper operation and leaktightness		AS00.00-Z-0005-01A

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation			ENGINE 276
BA07.03-P-1001-01D	Union nut, fuel line to fuel distributor	Stage 1	Nm	15
BA07.03-P-1001-01D	Union nut, fuel line to fuel distributor	Stage 2	∠°	90

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation		ENGINE 157	ENGINE 278
BA07.03-P-1001-01E	Union nut, fuel line to fuel distributor	Nm	22	22

INJECTION NOZZLES, INJECTION VALVES, LINES

Number	Designation			ENGINE 276
BA07.03-P-1007-01D	Cap on service connection	Plastic	Nm	2
BA07.03-P-1007-01D	Cap on service connection	Metal	Nm	15

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
BA07.03-P-1007-01E	Protective cap on service valve	Metal	Nm	15	15

AIR FILTER

Number	Designation		ENGINE 276.9
BA09.10-P-1001-01M	Bolt, air filter to cylinder head cover	Nm	9

AIR FILTER

Number	Designation		ENGINE 276.9
BA09.10-P-1002-01M	Bolt, air filter to air intake pipe support brace	Nm	9

HOUSING

Number	Designation		TRANSMISSION 722.9
BA27.40-P-1014-01A	Bolt, heat shield to transmission housing	Nm	9

FRAME FLOOR ASSEMBLY

Number	Designation		MODEL 207.3	MODEL 207.4
BA61.10-P-1003-01H	Bolt, rear reinforcement brace to frame floor assembly	Nm	24	24

FRAME FLOOR ASSEMBLY

Number	Designation		MODEL 212	MODEL 218
BA61.10-P-1003-01H	Bolt, rear reinforcement brace to frame floor assembly	Nm	24	24

Fig 6: Identifying Retainer Device (129 589 01 21 00)

Courtesy of MERCEDES-BENZ USA

Fig 7: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 8: Identifying Record Plug (129 589 00 91 00)

Courtesy of MERCEDES-BENZ USA