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

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ENGINES 651 in MODEL 212

Illustrated on model 204.9

Fig 1: Engine With Front Axle Carrier Remove/Install Components - Illustrated On Model 204.9 (1 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 2: Engine With Front Axle Carrier Remove/Install Components - Illustrated On Model 204.9 (2 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 3: Engine With Front Axle Carrier Remove/Install Components - Illustrated On Model 204.9 (3 Of 4)

Courtesy of MERCEDES-BENZ USA

Fig 4: Engine With Front Axle Carrier Remove/Install Components - Illustrated On Model 204.9 (4 Of 4)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

21.10.11

Value changed: screw/bolt, rear engine support to frame floor assembly

*BA22.10-P-1005-03E

	Remove/install
	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 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. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	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 poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.	Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
	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 from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
	Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid	Depressurize hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses.	AS00.00-Z-0013-01A
	Notes on bolted connections with self tapping screws		AH00.00-P-0007-01SF
1	Move selector lever into position "N"
2	Secure vehicle on vehicle lift		AR00.60-P-0100EWS
2	Secure vehicle on vehicle lift	Lifting platform retainer	Fig 10
	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
3	Disconnect ground line for on-board electrical system battery (G1)	Do not connect quiescent current retention unit.	AR54.10-P-0003EW
	Notes on battery	Do not connect quiescent current retention unit.	AH54.10-P-0001-01A
4	Drain air conditioning system		AR83.30-P-1760CW
5	Disconnect refrigerant lines to connecting point
6	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. Otherwise the clock spring contact will be destroyed.
6		Holding device	Figure
7	Remove bottom sections of soundproofing		AR94.30-P-5300EW
8	Drain coolant	Do not pressure-test cooling system until engine has reached operating temperature. Leaks can occur on the cylinder head gasket otherwise.	AR20.00-P-1142OMA
	Notes on coolant		AH20.00-N-2080-01A
		Mixture ratio for coolant	*BF20.00-P-1001-04A
		Tester cap	Fig 11
		Vacuum-type cooling system filler	Fig 13
9	Remove cylinder head cover trim
10	Remove engine air intake duct upstream of air filter housing
11	Remove air filter housing		AR09.10-P-1150CD
12	Disconnect electrical connector (3) at pressure differential sensor (DPF) (B28/8)
13	Disconnect electrical connectors (1, 2), unhook alternator/starter wiring harness (8) from bracket and place to one side
14	Disconnect alternator-starter-wiring harness (8) on front prefuse box (F32)	To do this remove cover (7), loosen nut (9) and unclip starter alternator wiring harness (8) up to engine.
14		Screw/bolt, guide pulley to major assembly carrier	*BA13.25-P-1002-01W
15	Detach coolant hoses (10, 11, 12 and 13) on engine	Henn coupling Check condition of coolant hoses (10, 11, 12 and 13), hose clamps and hose couplings and replace if necessary. Leaks can occur otherwise.	AR09.41-P-1311-01AL
16	Remove screw/bolt (14) and place coolant hose (13) to one side
17	Detach coolant hose (15) on bulkhead	Henn coupling To do this disconnect hose coupling (16).	AR09.41-P-1311-01AL
18	Release and detach vacuum line (17)
19	Unclip cover above radiator
20	Fix radiator in place with cable ties	Secure radiator above at least 2 points with cable ties. The radiator will fall down otherwise.
21	Disconnect charge air hose upstream and downstream of charge air cooler on the engine	To do this, release the safety clamps. Small quantities of oil and oil marks in the charge air hoses are normal, and are due to crankcase ventilation. Inspect sealing rings for damage and replace if required. Ensure the safety clamps are exactly installed. Leaks can occur otherwise.	AR09.41-P-8619CD
22	Separate lines at separation point of automatic transmission oil cooler
23	Loosen screw/bolt on clamp (18) and remove exhaust intermediate pipe from diesel particulate filter (19)	Bind up connecting pipe for exhaust system and secure flexible coupling element with assembly tool. Damage can occur on the flexible coupling element otherwise.
		Screw/bolt, connecting pipe clamp to diesel particulate filter	*BA49.10-P-1020-01AE
		Assembly tool	Fig 12
24	Remove shield (20) and disconnect electrical connector (21)
25	Detach ground line (22) on transmission	Screw/bolt, ground strap to transmission	*BA15.10-P-1002-05C
26	Disconnect fuel lines (23)	Open tank cap in order to reduce the overpressure in the tank. Mark fuel lines in order to exclude any later mix up. Seal connections. Replace hose clamps.
		Clamp	Fig 5
		Set of stop plugs	Figure
27	Remove shift rod (25) from range selector lever of transmission	To do this loosen securing clamp (24) and remove shift rod (25) from selector lever Replace securing clamp (24).
28	Detach underbody panel (26).
29	Remove heat shield (27) in area of propeller shaft center support bearing	Start by removing bolts (28).
30	Unscrew screw/bolts (29) and remove vibration damper (30)	Screw/bolt, vibration damper to transfer case	*BA28.10-P-1007-01E
31	Mark propeller shaft	Apply color markings to the transmission to indicate position of the propeller shaft relative to the output flange. This ensures that the components are reinstalled at the factory installation position.
32	Remove propeller shaft at transmission	To do this detach fitting sleeves from flexible couplings. The flexible coupling remains on the propeller shaft.	AR41.10-P-0050-09TX
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
		Check flexible coupling for wear and damage; replace if necessary. Install new self-locking nuts.
		Self-locking nut, flex disk to transmission or front propeller shaft	*BA41.10-P-1001-01I
33	Remove front axle shafts	Only with 4MATIC	AR33.30-P-0620CWX
34	Remove rear section of front wheel well panel
35	Detach front door sill panels
36	Remove diagonal struts (33)	The screw/bolts of the diagonal struts (33) may only be securely tightened when the vehicle is standing with its wheels on the ground.
		Screw/bolt, diagonal strut mount on front axle carrier/longitudinal member	*BA61.10-P-1004-01H
		Set of engine mount wrenches	Fig 6
37	Disconnect steering coupling		AR46.10-P-8000EW
38	Expose electrical line for electric power steering actuator motor and pull out
38		Release and pull out the line from the clips and clamps. Ensure that the connectors are not damaged or tear off.
39	Disconnect engine mount electrical connectors in wheel well
40	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	Ensure even alignment of support plates. Vehicle lift for major assemblies/scissors-type pallet forklift
41	Remove rear engine crossmember (32)	Start by removing screw/bolts (31). The rear engine crossmember (32) remains attached to transmission.
41	Remove rear engine crossmember (32)	Screw/bolt, rear engine support to frame floor assembly	*BA22.10-P-1005-03E
42	Unscrew screw/bolt (35) on front axle carrier from longitudinal members	Replace bolts (35).
42		Screw/bolt, front axle carrier to longitudinal member	*BA33.10-P-1001-01M
43	Lower engine transmission unit with front axle carrier	Ensure that engine does not scrape on components during removal or installation. Damage can occur to the engine or other components otherwise. Pay attention to correct seating of the rubber supports for the radiator support.
44	Install in the reverse order
45	Perform wheel alignment check		AR40.20-P-0200EW
46	Read out fault memory and erase	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.
46	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
	Checking
47	Check engine oil level	The engine oil level must lie between "Min" and "Max". Engine damage can occur otherwise.	AR18.00-P-3035-01T
		Dipstick	Fig 7
		Oil level check	*BF18.00-P-1001-03AC
		Oil level check	*BF18.00-P-1002-03AC
		Oil level check	*BF18.00-P-1003-03AC
		Oil level check	*BF18.00-P-1004-03AC
48	Check transmission oil level and correct if necessary		AR27.00-P-0270SYZ
49	Inspect cooling system for leaks	For engines with new cylinder head gasket: do not pry off cooling system until engine has reached operating temperature. Leaks can occur otherwise.	AR20.00-P-1010CW
50	Check installation position and unobstructed movement of all components of the exhaust system		AR20.00-P-1010CW
51	Check for leaks with engine running

OIL PAN

Number	Designation		Engine 651
BA01.45-P-1003-01S	Oil drain screw on oil pan	Nm	30

BELT TENSIONING DEVICE

Number	Designation			Engine 651 except 651.901/930	Engine 651.901/930
BA13.25-P-1002-01W	Screw/bolt, guide pulley to major assembly carrier	M8	Nm	25	45
BA13.25-P-1002-01W	Screw/bolt, guide pulley to major assembly carrier	M10	Nm	45	-

GROUND STRAP

Number	Designation			Model 212
BA15.10-P-1002-05C	Screw/bolt, ground strap to transmission	M8	Nm	-
BA15.10-P-1002-05C	Screw/bolt, ground strap to transmission	M10	Nm	39

ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number	Designation		Model 212 except 4MATIC	Model 212 4MATIC
BA22.10-P-1005-03E	Screw/bolt, rear engine support to frame floor assembly	Nm	70	70

TRANSFER CASE COMPLETE

Number	Designation		Transmission 722.96
BA28.10-P-1007-01E	Screw/bolt, vibration damper to transfer case	Nm	40

FRONT AXLE CARRIER

Number	Designation		Model 212
BA33.10-P-1001-01M	Screw/bolt, front axle carrier to longitudinal member	Nm	180
BA33.10-P-1002-01M	Fixing of support (strut)	Nm	110

PROPELLER SHAFT

Number	Designation			Model 212
BA41.10-P-1001-01I	Self locking nut, flex disk to transmission or front propeller shaft	M12	Nm	68

EXHAUST SYSTEM

Number	Designation		Engines 642, 651 in model 212
BA49.10-P-1020-01AE	Screw/bolt, connecting pipe clamp to diesel particulate filter	Nm	35

FRAME FLOOR ASSEMBLY

Number	Designation		Model 212
BA61.10-P-1004-01H	Screw/bolt, diagonal strut mount on front axle carrier/longitudinal member	Nm	60

REFRIGERANT COMPRESSOR

Number	Designation		Engine 651 except model 204, 207
BA83.55-P-1001-01W	Screw/bolt, refrigerant compressor to major assembly carrier	Nm	20
BA83.55-P-1002-01W	Screw/bolt, refrigerant compressor to engine support	Nm	20

MIXTURE RATIO FOR COOLANT

Number	Designation			ENGINE all
BF20.00-P-1001-04A	Mixture ratio for coolant	Antifreeze/water	up to -37°C	50/50
		Antifreeze/water	up to -45°C	55/45
		Specifications for service products	Specification	Coolant (Specification 310.1). See https://bevo.mercedes-benz.com/index.php?language_id=1
		Specifications for service products	Specification	Anticorrosion/antifreeze agents (Specification 325.0). See https://bevo.mercedes-benz.com/index.php?language_id=1

OIL LEVEL CHECK

Number	Designation			Engine 651.924 in model 212
BF18.00-P-1001-03AC	Oil level	Maximum	mm	117
BF18.00-P-1001-03AC	Oil level	Minimum	mm	94
BF18.00-P-1002-03AC	Dipstick indication 97 mm to 112 mm (oil level too low)	97 mm	Replenish oil quantity in liters	2
		99 mm	Replenish oil quantity in liters	1.5
		100 mm	Replenish oil quantity in liters	1.5
		101 mm	Replenish oil quantity in liters	1.5
		102 mm	Replenish oil quantity in liters	1.5
		103 mm	Replenish oil quantity in liters	1.5
		104 mm	Replenish oil quantity in liters	1
		105 mm	Replenish oil quantity in liters	1
		106 mm	Replenish oil quantity in liters	1
		107 mm	Replenish oil quantity in liters	1
		108 mm	Replenish oil quantity in liters	1
		109 mm	Replenish oil quantity in liters	0.5
		110 mm	Replenish oil quantity in liters	0.5
		111 mm	Replenish oil quantity in liters	0.5
		112 mm	Replenish oil quantity in liters	0.5
BF18.00-P-1003-03AC	Oil dipstick indication 114 mm to 118 mm (oil level correct)	114 mm	Oil quantity in liters	0.0
		116 mm	Oil quantity in liters	0.0
		118 mm	Oil quantity in liters	0.0
BF18.00-P-1004-03AC	Oil dipstick indication 120 mm to 124 mm (oil level too high)	120 mm	Extract oil quantity in liters	-0.5
		121 mm	Extract oil quantity in liters	-0.5
		122 mm	Extract oil quantity in liters	-0.5
		123 mm	Extract oil quantity in liters	-0.5
		124 mm	Extract oil quantity in liters	-1