Remove/install engine with front axle carrier - AR01.10-P-2500OGE
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ENGINE 642 in MODEL 212.08/09/28/29, 218.39
Shown on model 204.0/2
Shown on model 204.9
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Notes on coolant | AH20.00-N-2080-01A | ||
| Notes on AIRmatic | AH32.22-P-1000-02EW | ||
| Notes on repair work on suspension components | AH00.00-P-0100-01A | ||
| Notes on automatic transmission | AH27.19-P-0001-01NKB | ||
| Remove/install | |||
| 1 | Relieve all pressure in front suspension struts with diagnostic system | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with CODE 489 (AIRMATIC) |
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| AD00.00-P-2000-04A | |||
| 2 | Deactivate easy entry/exit feature | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with CODE 275 (Memory package) |
|
| 3 | Move front wheels to straight-ahead position and secure steering wheel | The steering wheel must not be turned when detaching steering coupling. Otherwise the clock spring contact will be destroyed. |
|
| Figure | |||
| 4 | Set gear selector switch to position "N" and release parking brake | ||
| 5 | Detach ground line from battery | AR54.10-P-0003EW | |
| 6 | Secure vehicle on vehicle lift | AR00.60-P-0100EWS | |
| 7 | Remove cold air suction bridge | AR20.40-P-5050EW | |
| 8 | Suction refrigerant out of air conditioning | AR83.30-P-1760CW | |
| 9 | Disconnect wiring harness in engine compartment | ||
| 10 | Disconnect vacuum line (1) at connecting point (arrow) | AR43.10-P-0355EW | |
| 11 | Remove right and left air filter housing | AR09.10-P-1150SXI | |
| 12 | Empty power steering expansion reservoir | ENGINE 642 in MODEL 212.08/09/28/29 | |
| Figure | |||
| 13 | Remove return line (2) on power steering expansion reservoir | ||
| 14 | Remove return line (2) on P/S cooler | ||
| 15 | Disconnect refrigerant line (7) at connecting point (arrow) | Fig 4 | |
| 16 | Fasten radiator to radiator crossmember using cable ties | ||
| 17 | Remove coolant lines (3, 4, 5, 6) | AR09.41-P-1311-01AL | |
| 18 | Remove coolant line (13) at firewall | AR09.41-P-1311-01AL | |
| 19 | Remove charge air hose on engine charge air duct downstream of charge air cooler and set aside | AR09.41-P-1311-01AL | |
| 20 | Remove charge air hose upstream of charge air cooler | ||
| 21 | Remove front wheels | ||
| AP40.10-P-4050EW | |||
| 22 | Remove bottom sections of soundproofing | AR94.30-P-5300EW | |
| 23 | Disconnect wiring harness on transmission and underfloor | ||
| 24 | Remove refrigerant line (11) on condenser and close off openings with stop plugs | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 |
*BA83.30-P-1022-01A |
| Figure | |||
| 25 | Drain coolant at radiator | AR20.00-P-1142OGE | |
| 26 | Remove oil lines for A/T (12) at the front connecting points | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with TRANSMISSION 722.9 | |
| AR27.55-P-0600CWX | |||
| 27 | Remove exhaust system holder from transmission and frame floor assembly | *BA49.10-P-1023-01AE | |
| *BA49.10-P-1025-01AE | |||
| 28 | Disconnect exhaust system at diesel particulate filter connecting point at exhaust pipe | AR49.10-P-7100EWI | |
| 29 | Loosen right and left hand underfloor paneling | ||
| 30 | Remove center strut on frame floor assembly | ||
| 31 | Remove heat shield im the area of the propeller shaft center support bearing | ||
| 32 | Detach propeller shaft at transmission | AR41.10-P-0050EW | |
| 33 | Disconnect steering coupling | AR46.10-P-8000EW | |
| 34 | Remove the right bracket at soundproofing bottom section | ||
| 35 | Remove brake caliper with from brake caliper support steering knuckles and fasten with attached lines to suspension strut | ENGINE 642 in MODEL 212.08/09/28/29, 218.39divided floating caliper brake | AR42.10-P-0070EWC |
| ENGINE 642 in MODEL 212.08/09/28/29undivided 1-piston floating caliper brake | AR42.10-P-0070EWB | ||
| ENGINE 642 in MODEL 212.08/09/28/29, 218.394-piston fixed-caliper brake | AR42.10-P-0070EWA | ||
| 36 | Disconnect electrical connections from rpm sensors at front left and right and front right brake pad contact sensor and unclip electrical lines from the brackets | AR33.10-P-0100-06CW | |
| 37 | Remove front level sensor at strut rod | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with CODE 488 (Steel/air suspension) or with automatic headlamp range adjustmentENGINE 642 in MODEL 212.08/09/28/29, 218.39 with CODE 489 (AIRMATIC) or with automatic headlamp range adjustment |
|
| 38 | Remove torsion bar linkage from torsion bar | *BA32.20-P-1001-02P | |
| 39 | Remove suspension struts from steering knuckles | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 without CODE 489 (AIRMATIC) |
AR32.25-P-1017EW |
| ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with CODE 489 (AIRMATIC) |
AR32.25-P-1017EWA | ||
| 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 | |
| 40 | Remove fuel lines from fuel pipes and close off openings with stop plugs | Figure | |
| 41 | Support front axle carrier with lifting platform and aggregate mount and secure whole engine transmission unit against slipping and falling down with a tensioning strap | ||
| 000 588 03 62 00 Lifting platform | WS01.00-P-0091A | ||
| 42 | Remove rear engine crossmember from frame floor assembly | ||
| Bolt, rear engine support to frame floor assembly | *BA22.10-P-1005-03E | ||
| 43 | Remove support struts (21) from front axle carrier and frame floor assembly | *BA33.10-P-1002-01M | |
| 44 | Remove screw/bolts on front axle carrier from longitudinal members | ||
| Notes on bolted connections with self tapping screws | AH00.00-P-0007-01SF | ||
| *BA33.10-P-1001-01M | |||
| 45 | Lower engine-transmission unit with front axle carrier | The engine must not lie on the vehicle. Damage can occur to lines and detachable parts otherwise. |
|
| 46 | Install in the reverse order | ||
| Check | |||
| 47 | Check and correct transmission oil level | ENGINE 642 in MODEL 212.08/09/28/29, 218.39 with TRANSMISSION 722.9 | |
| AR27.00-P-0270SYZ | |||
| 48 | Fill power steering pump and bleed | ENGINE 642 in MODEL 212.08/09/28/29 | |
| AR46.30-P-0010EW | |||
| 49 | Check engine oil level and correct | ||
| AP18.00-P-0101EWO | |||
| 50 | Perform wheel alignment check | AR40.20-P-0200EW | |
| 51 | Read out fault memory using the diagnostic system and delete | ||
| 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 | |
| 52 | Carry out an engine test run, checking the engine for proper operation and leaktightness |
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)
| Number | Designation | MODEL 212 | MODEL 218 | |||
|---|---|---|---|---|---|---|
| BA22.10-P-1005-03E | Bolt, rear engine support to frame floor assembly | M10x22 | Silver | Nm | 70 | 70 |
| Black | Nm | 55 | 55 | |||
| M10x24 | Black | Nm | - | - | ||
| M10x38 | Nm | - | - | |||
FRONT AXLE TORSION BAR
| Number | Designation | MODEL 212 | MODEL 218 | |
|---|---|---|---|---|
| BA32.20-P-1001-02P | Nut, link rod to stabilizer bar | Nm | 98 | 98 |
FRONT AXLE CARRIER
| Number | Designation | MODEL 212 | MODEL 218 | |
|---|---|---|---|---|
| BA33.10-P-1001-01M | Bolt, front axle carrier to longitudinal member | Nm | 180 | 180 |
FRONT AXLE CARRIER
| Number | Designation | MODEL 212 | MODEL 218 | |
|---|---|---|---|---|
| BA33.10-P-1002-01M | Fixing of support (strut) | Nm | 110 | 110 |
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 642, 651 in MODEL 212 | ENGINE 642, 651 in MODEL 218 | ||
|---|---|---|---|---|---|
| BA49.10-P-1025-01AE | Bolt, exhaust system to main floor panel | M8 | Nm | 20 | 20 |
| M10 | Nm | 50 | 50 | ||
AIR CONDITIONING
| Number | Designation | MODEL 212 | MODEL 218 | |
|---|---|---|---|---|
| BA83.30-P-1022-01A | Screw/bolt, line to condenser | Nm | 8 | 8 |