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

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ENGINE 642 in MODEL 207 

ENGINE 642 in MODEL 212, 218 except 4MATIC 

Shown on model 212.0 

Fig 1: Engine Remove/Install Components - Shown On Model 212 (1 Of 2)
G09973670Courtesy of MERCEDES-BENZ USA
Fig 2: Engine Remove/Install Components - Shown On Model 212 (2 Of 2)
G09973671Courtesy of MERCEDES-BENZ USA

Shown on vehicle with hydraulic power steering pump 

Fig 3: Engine Remove/Install Components - Shown With Hydraulic Power Steering Pump
G09973672Courtesy of MERCEDES-BENZ USA

Only if transmission 711.6 is fitted 

Fig 4: Engine Remove/Install Components - Only Transmission 711.6 Fitted
G09973673Courtesy of MERCEDES-BENZ USA
Fig 5: Engine Remove/Install Components - Only Transmission 711.6 Fitted
G09973674DANGERDANGERDANGERDANGERDANGERNOTESNOTESREMOVINGINSTALLINGNOTESIMPORTANTREFER TO MAINTENANCEINSTALLATION NOTESINSTALLATION IMPORTANTINSTALLATION NOTESINSTALLATION IMPORTANTREFER TO SHOP-MADE TOOLSINSTALLATION IMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTINSTALLATION IMPORTANTIMPORTANTSPECIAL TOOLINSTALLATION IMPORTANTIMPORTANTSPECIAL TOOLIMPORTANTINSTALLATION IMPORTANTSPECIAL TOOLIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLIMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLINSTALLATION NOTESSPECIAL TOOLTORQUE SPECIFICATIONNOTESDANGERNOTESTORQUE SPECIFICATIONSPECIAL TOOLNOTESTORQUE SPECIFICATIONIMPORTANTIMPORTANTINSTALLATION IMPORTANTIMPORTANTINSTALLATION IMPORTANTTORQUE SPECIFICATIONINSTALLATION IMPORTANTTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLIMPORTANTTORQUE SPECIFICATIONSPECIAL TOOLNOTESREFER TO SELF-DIAGNOSTIC SYSTEMSINSPECTFLUID SPECIFICATIONTORQUE SPECIFICATIONCourtesy of MERCEDES-BENZ USA
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
DANGER 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
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from 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
DANGER 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
DANGER Risk of injury  to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning  from swallowing hydraulic fluid. Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. AS00.00-Z-0013-01A
NOTES Notes on self-locking nuts and bolts   AH00.00-N-0001-01A
NOTES Notes on bolted connections with self tapping screws   AH00.00-P-0007-01SF
REMOVINGINSTALLING Remove/install     
1 Disconnect ground line at the on-board electrical system battery   AR54.10-P-0003EW
NOTES Notes on battery   AH54.10-P-0001-01A
IMPORTANT Do not connect no-load current retention unit.
2 Drain engine oil    
REFER TO MAINTENANCE   AP18.00-P-0101EWO
INSTALLATION NOTES
Replace sealing ring for drain screw. Leaks can occur otherwise.
INSTALLATION IMPORTANT Check engine oil level with the oil dipstick for about 5 minutes after stopping the warmed up engine.
3 Secure vehicle on vehicle lift ENGINE 642 in MODEL 207 AR00.60-P-0100CW
ENGINE 642 in MODEL 212, 218 except 4MATIC AR00.60-P-0100EWS
4 Remove bottom sections of soundproofing   AR94.30-P-5300EW
5 Drain coolant ENGINE 642 in MODEL 207 AR20.00-P-1142CW
ENGINE 642 in MODEL 212, 218 except 4MATIC
INSTALLATION NOTES
Do not check the pressure of the cooling system until engine has reached its operating temperature.
Leaks can occur on the cylinder head gasket otherwise.		 AR20.00-P-1142OGE
6 Remove engine cover INSTALLATION IMPORTANT Ensure correct seating of the engine cover.  
7 Remove engine air intake duct upstream of the air filter housing on both sides    
8 Remove air filter housing on both sides ENGINE 642 in MODEL 218 except 4MATIC AR09.10-P-1150SXI
9 Remove fan unit ENGINE 642 in MODEL 207 AR20.40-P-5050CW
ENGINE 642 in MODEL 212, 218 except 4MATIC AR20.40-P-5050EW
10 Attach guard plate for radiator and condenser    
REFER TO SHOP-MADE TOOLS WF58.50-P-0110-01A
11 Remove engine charge air duct upstream of charge air cooler   AR09.41-P-8623OGE
12 Open clutch and remove charge air hose on engine charge air duct downstream of charge air cooler   AR09.41-P-1311-01AL
INSTALLATION IMPORTANT Thoroughly clean connections. Check catch spring for correct seating.
13 Remove coolant hose (15) from thermostat housing   AR20.20-P-7441-01RQ
INSTALLATION IMPORTANT Thoroughly clean connections. Check catch spring for correct seating.
14 Detach return line (16) from thermostat housing INSTALLATION IMPORTANT Check hose clamp for damage.  
15 Remove coolant hose (11) at the fitting (10)   AR20.20-P-7441-01RQ
INSTALLATION IMPORTANT Thoroughly clean connections. Check catch spring for correct seating.
16 Detach coolant hose (13) on fitting (10) INSTALLATION IMPORTANT Check clamp for firm seating.  
17 Remove coolant hose (17) at firewall   AR20.20-P-7441-01RQ
INSTALLATION IMPORTANT Thoroughly clean connections. Check catch spring for correct seating.
18 Disconnect electrical connection (1)    
19 Remove fender liner in right fender    
20 Disconnect Electrical connection (2) on CDI control unit    
21 Unscrew ground lines (3)    
22 Loosen cable tie (4), unclip cover (5) from cable duct and remove cover (5) INSTALLATION IMPORTANT Replace cable tie (4).  
23 Loosen cable tie in cable duct, remove wiring harness and put aside wiring harness on engine    
24 Disconnect alternator-starter-wiring harness (6) on front prefuse box IMPORTANT To do this remove cover (7), loosen nut (8) and unclip starter alternator wiring harness (6) up to engine.  
25 Release and detach vacuum line (14)    
26 Extract oil from power steering pump (23) expansion reservoir (21) ENGINE 642 in MODEL 212, 218 except
4MATIC		  
SPECIAL TOOL Hand pump Figure
27 Detach return hose (20) from expansion reservoir (21) and close off with a suitable grommet ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC
INSTALLATION IMPORTANT Check clamp for firm seating.
IMPORTANT Collect the discharged oil using a rag.		  
SPECIAL TOOL Record plug Figure
28 Disconnect hose (22) from power steering pump (23) and seal with a suitable stop plug ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC
IMPORTANT Collect the discharged oil using a rag.
INSTALLATION IMPORTANT Check clamp for firm seating.		  
SPECIAL TOOL Record plug Figure
29 Detach hose (24) from power steering pump (23) and seal with a suitable stop plug ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC
IMPORTANT To do this remove screw/bolt (25) and remove high-pressure line (24). Collect the discharged oil using a rag.
INSTALLATION IMPORTANT Replace O-rings.		  
TORQUE SPECIFICATION *BA46.30-P-1004-01R 
ENGINE 642 in MODEL 207  
TORQUE SPECIFICATION *BA46.30-P-1004-01T 
ENGINE 642 in MODEL 212 except 4MATIC  
SPECIAL TOOL Record plug Figure
30 Remove screw/bolt (26) for refrigerant line (27) on oil filter housing    
31 Remove poly-V belt   AR13.20-P-0001OGE
32 Disconnect electrical connection on A/C compressor    
33 Remove refrigerant compressor bolts IMPORTANT Attach A/C compressor at side in bottom of engine compartment with lines connected.  
TORQUE SPECIFICATION Refrigerant compressor bolt *BA83.55-P-1005-01A 
34 Disconnect oil lines (30) from transmission on engine radiator and close with suitable stop plug ENGINE 642 in MODEL 207 with TRANSMISSION 722.9
ENGINE 642 in MODEL 212, 218 with TRANSMISSION 722.9 except 4MATIC		  
SPECIAL TOOL Record plug Figure
35 Detach steering oil line (31) on ALT bracket (32) ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC		  
36 Detach fuel lines (35) at fuel pipes and close with suitable stop plug INSTALLATION NOTES
Replace collar clamps.
Leaks can occur otherwise.		  
SPECIAL TOOL Record plug Figure
37 Detach ground line (34) on transmission TORQUE SPECIFICATION Bolt, ground strap to transmission *BA15.10-P-1002-05C 
38 Disconnect Electrical connection on oil temperature sensor NOTES
Remove electrical connection from the assembly areas.
Damage will occur during engine removal otherwise.		  
39 Disconnect Electrical connection (33) ENGINE 642 in MODEL 207 with TRANSMISSION 722.9
ENGINE 642 in MODEL 212, 218 with TRANSMISSION 722.9 except 4MATIC		  
40 Remove holder (36) for the wiring harness and bind up to the side with wiring harness ENGINE 642 in MODEL 207 with TRANSMISSION 722.9  
41 Remove heat shield (37) and disconnect underlying electrical connection ENGINE 642 in MODEL 207 with TRANSMISSION 722.9
ENGINE 642 in MODEL 212, 218 with TRANSMISSION 722.9 except 4MATIC		  
42 Disconnect Electrical connection (29) for backup lamp switch (S162) ENGINE 642 in MODEL 207 with TRANSMISSION 711.6  
DANGER Risk of poisoning  from swallowing brake fluid. Risk of injury  from skin and eye contact with brake fluid 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
43 Disconnect line connection (28) for clutch operating mechanism and close with suitable stop plug ENGINE 642 in MODEL 212 with TRANSMISSION 711.6 except 4MATIC  
NOTES Brake fluid notes   AH42.50-P-0001-01A
TORQUE SPECIFICATION Union nut for clutch operating system line on hose *BA25.20-P-1002-01B 
SPECIAL TOOL Record plug Figure
44 Disconnect hose clamp (38) on exhaust pipe NOTES
Tie up exhaust pipe using a cable tie. Damage can occur to the exhaust pipe otherwise.		  
TORQUE SPECIFICATION Nut, clamp for rear muffler to pipe *BA49.10-P-1031-01AE 
45 Prop up transmission using telescopic lifter    
46 Remove rear engine crossmember ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC
IMPORTANT The rear engine mount remains screwed onto transmission.		 AR22.10-P-1180CW
47 Mark propeller shaft IMPORTANT Attach colored marking of the propeller shaft position to the output flange on the transmission.
INSTALLATION IMPORTANT The installation position established at the works should be restored.		  
48 Detach propeller shaft at transmission ENGINE 642 in MODEL 212, 218 except 4MATIC AR41.10-P-0050EW
ENGINE 642 in MODEL 207
IMPORTANT The flexible coupling remains on the propeller shaft.
INSTALLATION IMPORTANT Install new self-locking nuts. Check flexible coupling for wear and damage.		 AR41.10-P-0050CW
TORQUE SPECIFICATION Self-locking nut, flexible coupling to transmission or front propeller shaft *BA41.10-P-1001-01I 
49 Detach center shifter console and shift rod on transmission ENGINE 642 in MODEL 212 with TRANSMISSION 711.6 AR26.60-P-0600-02CW
INSTALLATION IMPORTANT Lightly grease ball joint and safety bolt.  
Long-life grease *BR00.45-Z-1001-06A 
50 Install rear engine crossmember ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC		 AR22.10-P-1180CW
51 Remove telescopic lifter    
52 Remove lower screw/bolts on the front right engine mount TORQUE SPECIFICATION Bolt, front engine mount to front axle carrier *BA22.10-P-1002-03E 
53 Hook engine hoists into engine lifting eyes    
54.1 Remove upper screw/bolts on left and right engine mount ENGINE 642 in MODEL 207
ENGINE 642 in MODEL 212 except 4MATIC		  
TORQUE SPECIFICATION Bolt, front engine mount to engine support *BA22.10-P-1001-03E 
SPECIAL TOOL Engine mount wrench set Fig 7
54.2 Loosen upper screw/bolts on left and right engine mount ENGINE 642 in MODEL 218 except 4MATIC
IMPORTANT Fully screw in screw/bolt for left engine mount after loosening. Just remove screw/bolt for the right engine mount by about 10 mm.		  
TORQUE SPECIFICATION Bolt, front engine mount to engine support *BA22.10-P-1001-03E 
SPECIAL TOOL Engine mount wrench set Fig 7
55 Slightly raise engine and turn RH engine mount inwards ENGINE 642 in MODEL 218 except 4MATIC  
56 Lower engine towards the rear and lift out NOTES
Ensure that engine does not scrape on components during removal or installation. Damage can occur to the engine or other components otherwise.		  
57 Install in the reverse order    
58 Bleed clutch operating system ENGINE 642 in MODEL 212 with TRANSMISSION 711.6 except 4MATIC -
59 Fill and bleed power steering pump (23) ENGINE 642 in MODEL 207 AR46.30-P-0010CW
ENGINE 642 in MODEL 212 except 4MATIC AR46.30-P-0010EW
60 Read out and clear fault memory using the diagnostic system    
REFER TO SELF-DIAGNOSTIC SYSTEMS AD00.00-P-2000-04A
INSPECT Check     
61 Check shift mechanism for ease of movement ENGINE 642 in MODEL 207 with TRANSMISSION 711.6  
62.1 Check transmission oil level ENGINE 642 in MODEL 212 with TRANSMISSION 711.6 except 4MATIC  
FLUID SPECIFICATION Transmission oil *BF26.10-P-1001-01G 
TORQUE SPECIFICATION Oil filler screw to transmission housing (thread oiled) *BA26.40-P-1005-01E 
62.2 Check transmission oil level and correct if necessary ENGINE 642 in MODEL 207 with TRANSMISSION 722.9, 725.0
ENGINE 642 in MODEL 212, 218 with TRANSMISSION 722.9
except 4MATIC ENGINE 642 in MODEL 212, 218 with TRANSMISSION 725.0 except 4MATIC		  
  AR27.00-P-0270W
63 Check installation position and unobstructed movement of all components of the exhaust system    
GROUND STRAP

Number Designation MODEL 207 MODEL 212
BA15.10-P-1002-05C Bolt, ground strap to transmission M8 Nm 16 25
M10 Nm - 39
GROUND STRAP

Number Designation MODEL 218
BA15.10-P-1002-05C Bolt, ground strap to transmission M8 Nm -
M10 Nm 39
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number Designation MODEL 207 MODEL 212
BA22.10-P-1001-03E Bolt, front engine mount to engine support M10   Nm 50 50
M12 Stage 1 Nm 85 85
Stage 2 ∠° 90 90
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number Designation MODEL 218
BA22.10-P-1001-03E Bolt, front engine mount to engine support M10   Nm 50
M12 Stage 1 Nm 85
Stage 2 ∠° 90
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number Designation MODEL 207 MODEL 212
BA22.10-P-1002-03E Bolt, front engine mount to front axle carrier M8 Nm 28 28
ENGINE MOUNT, ENGINE SUPPORT (ENGINE SIDE)

Number Designation MODEL 218
BA22.10-P-1002-03E Bolt, front engine mount to front axle carrier M8 Nm 28
CLUTCH OPERATING SYSTEM

Number Designation TRANSMISSION 711.6 in MODEL 117, 156, 171, 172, 176, 203, 204, 207, 212, 242, 246
BA25.20-P-1002-01B Union nut for clutch operating system line on hose Nm 16
HOUSING

Number Designation TRANSMISSION 711.67
BA26.40-P-1005-01E Oil filler screw to transmission housing (thread oiled) Nm 33
PROPELLER SHAFT

Number Designation MODEL 207 MODEL 212
BA41.10-P-1001-01I Self-locking nut, flexible coupling to transmission M12 or front propeller shaft Nm 68 68
PROPELLER SHAFT

Number Designation MODEL 218
BA41.10-P-1001-01I Self-locking nut, flexible coupling to transmission or front propeller shaft M12 Nm 68
POWER STEERING PUMP

Number Designation MODEL 207
BA46.30-P-1004-01R Attachment, high-pressure expansion hose of rack-and-pinion steering to power steering pump or tandem pump Union nut Nm -
Banjo bolt Nm -
Bolt M8 Nm 18
POWER STEERING PUMP

Number Designation MODEL 212
BA46.30-P-1004-01T Attachment, high pressure expansion hose to power steering pump Union nut Nm 40
Banjo bolt Nm 45
Screw M8 Nm 18
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 207 ENGINE 642, 651 in MODEL 212
BA49.10-P-1031-01AE Nut, clamp for rear muffler to pipe Nm 35 35
EXHAUST SYSTEM

Number Designation ENGINE 642, 651 in MODEL 218
BA49.10-P-1031-01AE Nut, clamp for rear muffler to pipe Nm 35
REFRIGERANT COMPRESSOR

Number Designation ENGINE 642 in MODEL 207 ENGINE 642 in MODEL 212
BA83.55-P-1005-01A Refrigerant compressor bolt Nm 20 20
REFRIGERANT COMPRESSOR

Number Designation ENGINE 642 in MODEL 218
BA83.55-P-1005-01A Refrigerant compressor bolt Nm 20
COMPLETE TRANSMISSION

Number Designation TRANSMISSION 711.670
BF26.10-P-1001-01G Transmission oil Filling capacity Liter 1, 8
Specification   Gear oils (Specification 235.10). MB 235.10 manual transmission oil A 001 989 84 03
Fig 6: Identifying Hand Pump (210 589 00 71 00)
G09973675Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Engine Mount Wrench Set (001 589 01 16 00)
G09973676Courtesy of MERCEDES-BENZ USA
Fig 8: Identifying Record Plug (129 589 00 91 00)
G09973677Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11
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