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Remove/install engine - AR01.10-P-2400EMG

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ENGINES 156 in MODEL 212 

Fig 1: Engine Remove/Install Components (1 Of 2)
G09973664Courtesy of MERCEDES-BENZ USA
Fig 2: Engine Remove/Install Components (2 Of 2)
G09973665Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

23.11.10 Value modified: Bolt, clamp plate, high-pressure line/return line to rack-and-pinion steering control head   *BA46.20-P-1003-01N 
REMOVINGINSTALLING Remove/install     
DANGER 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
DANGER 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 the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
1 Selector lever in position "N"    
2 Detach ground line from battery   AR54.10-P-0003EW
NOTES Notes on battery AH54.10-P-0001-01A
3 Secure vehicle on vehicle lift   AR00.60-P-0100EWS
SPECIAL TOOL Lifting platform retainer Fig 6
4 Remove air filter housing (1) and engine air intake ducts (1a) upstream of air filter   AR09.10-P-1150CMG
5 Remove fan shroud (22)   AR20.40-P-5050EW
6 Detach purging vacuum hose (2) from purging switchover valve INSTALLATION IMPORTANT Install new clamp  
7 Disconnect vacuum hose (4) at intake manifold    
8 Extract oil from power steering expansion reservoir SPECIAL TOOL Fig 3
9 Detach engine wiring harness   AR01.00-P-2410CMG 
10 Detach exhaust bracket from transmission (27)   AR49.10-P-7100EW
11 Detach catalytic converters from exhaust manifolds and secure them to prevent them from falling down INSTALLATION NOTES On vehicles with engine damage, the exhaust system must be checked for swarf before assembly, and the swarf, if any, must be removed to prevent any consequential damage. AR49.10-P-7100EW
12 Support transmission (27) with transmission jack and platform    
13 Remove rear engine support (11) and rear engine mount (12)   AR22.10-P-1180CMG
NOTES Notes on bolted connections with self tapping screws AH00.00-P-0007-01SF
14 Mark propeller shaft (13) IMPORTANT Apply color markings to the transmission (27) to indicate the position of the propeller shaft (13) relative to the flange. This will allow the components to be reinstalled at the factory installation position.  
15 Detach propeller shaft (13) from transmission (27) IMPORTANT The flexible coupling remains on the propeller shaft (13).  
TORQUE SPECIFICATION *BA41.10-P-1001-01I 
16 Disconnect ISM electrical connector on automatic transmission (27)    
17 Install rear engine support (11) IMPORTANT Installation takes place without the rear engine mount (12). AR22.10-P-1180CMG
18 Lower transmission (27) to rear engine support (11)    
19 Remove poly-V belt IMPORTANT Only remove poly-V belt from the belt pulley of A/C compressor (A9). AR13.20-P-0001CMG
20 Disconnect electrical connector at A/C compressor (A9)    
21 Detach A/C compressor (A9) at cylinder crankcase IMPORTANT Place A/C compressor (A9) in the engine compartment along with the connected lines and secure it to prevent it from falling down.  
22 Drain coolant from cylinder crankcase and radiator   AR20.00-P-1142CMG
NOTES Notes on coolant AH20.00-N-2080-01A
23 Drain engine oil  
REFER TO MAINTENANCE Engine oil and filter change Model 204 AP18.00-P-0101CMG
24 Detach speed-sensitive power steering electrical connector (15) at rack-and-pinion steering (23) NOTES Since this can be damaged when removing the engine.  
25 Disconnect and seal hydraulic lines (6) at the timing case of the rack-and-pinion steering (23) INSTALLATION IMPORTANT Replace seals.  
TORQUE SPECIFICATION *BA46.20-P-1003-01N 
SPECIAL TOOL Fig 5
26 Disconnect and seal engine oil lines (7) at flange connections (8) INSTALLATION IMPORTANT Replace sealing rings.  
SPECIAL TOOL Fig 5
27 Remove bracket for power steering hydraulic line to alternator    
28 Disconnect and seal oil cooling lines (9) at the separation point to the radiator from connecting lines (10) IMPORTANT Seal connections immediately. AR27.55-P-0600EV
SPECIAL TOOL Fig 5
29 Remove bolts on front engine mount to front axle carrier   AR22.10-P-1260CMG
30 Disconnect air line (14) of the secondary air injection pump at distributor (16)    
31 Disconnect coolant line (21) at coolant pump (20) and radiator and set aside    
32 Remove coolant line (17) from expansion reservoir (18) to thermostat housing    
33 Disconnect coolant line (19) from thermostat housing to radiator    
34 Disconnect coolant line (25) at splash wall SPECIAL TOOL Fig 5
35 Disconnect return line (24) at separation point of the power steering expansion reservoir    
DANGER 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
36 Reduce fuel pressure through service valve   AR07.03-P-1460-01TMG
SPECIAL TOOL Fig 4
37 Detach fuel line (3) TORQUE SPECIFICATION *BA07.03-P-1001-01C 
38 Attach guard plate for radiator/condenser    
REFER TO SHOP-MADE TOOLS Guard plate for radiator/condenser WF58.50-P-0110-01A
39 Attach engine hoist to engine lifting eyes    
40 Lift out engine IMPORTANT When hoisting the engine in/out, take care not to damage the steering coupling and the lines and cables, and do not allow the engine to come against the bulkhead.
IMPORTANT Slightly raise engine equally at front and back, pull slightly forward, then lower back and lift out.		  
41 Install in the reverse order    
42 Check engine oil level and adjust correctly  
REFER TO MAINTENANCE Engine oil and filter change Model 204 AP18.00-P-0101CMG
43 Fill and bleed power steering pump (5).   AR46.30-P-0010EW
44 Fill cooling system and check for leaks   AR20.00-P-1010CMG
DANGER Risk of accident  due to vehicle starting off 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
45 Conduct engine test run and check engine for leaks while it is running
46 Check oil level in transmission (27) and correct if necessary   AR27.00-P-0270W
47 Read out fault memory with STAR DIAGNOSIS and erase if necessary    
INJECTORS, INJECTION VALVES, LINES

Number Designation Engine 156
BA07.03-P-1001-01C Union nut, fuel line to fuel distributor Nm 20
STEERING GEAR

Number Designation Model 212 without 4-MATIC Model 212 with 4-MATIC
BA46.20-P-1003-01N Bolt, clamp plate, high-pressure line/return line to rack-and-pinion steering control head Nm 21 21
PROPELLER SHAFT

Number Designation Model 204 Model 212
BA41.10-P-1001-01I Self-locking nut, flex disk to transmission or front propeller shaft M12 Nm 68 68
Fig 3: Identifying Hand Pump (210 589 00 71 00)
G09973666Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Pressure Hose (119 589 04 63 00)
G09973667Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Set Of Stop Plugs (129 589 00 91 00)
G09973668Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Vehicle Lift Safety Device (171 589 01 31 00)
G09973669Courtesy of MERCEDES-BENZ USA
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