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

ENGINES 642 in MODEL 211.020/022/220/222/620 

Fig 1: Identifying Engine Components (1 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Engine Components (2 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Engine Components (3 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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 moving off. Wear closed and close-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
	Risk of death  caused by vehicle slipping or toppling off 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 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 explosion  caused by oxyhydrogen gas. Risk of poisoning and caustic burns  caused by swallowing battery acid. Risk of injury  caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
	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
	Notes on coolant		AH20.00-N-2080-01A
	Notes on battery		AH54.10-P-0001-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Disconnect battery ground line	Model 211.0	AR54.10-P-0003T
		Model 211.2	AR54.10-P-0003TA
2	Remove engine trim panel		AR01.10-P-2405TI
3	Remove intake air duct upstream of the air filter	Remove on both sides.
4	Unscrew heat shield over turbocharger
5	Extract fluid from power steering pump supply reservoir	Hand pump	Fig 5
6	Remove expansion reservoir for power steering pump		AR46.25-P-1000TI
7	Remove filling hose (5) for power steering pump	Installation:  Check hose clamp for tight seating; replace if necessary.
8	Detach high-pressure expansion hose (1) at power steering pump.	Installation:  Replace sealing ring.
9	Remove bottom sections of soundproofing		AR94.30-P-5300T
10	Drain coolant at radiator		AR20.00-P-1142TI
11	Unclip coolant hose at engine radiator	Installation:  In order to avoid leaks on engine check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease, as well as observe exact seating of detent springs. See: ↓
		Open and close coupling	AR09.41-P-1311-01AL
12	Unhook coolant hose at retaining clip	Installation:  Check retaining clip; replace if necessary.
13	Detach return hose at thermostat housing	Unhook retaining clip and lay return hose to one side. Installation:  Check hose clamp and retaining clip; replace if necessary.
14	Unclip coolant hose (11) from engine radiator at fitting (10)	Installation:  In order to avoid leaks on engine check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease, as well as observe exact seating of detent springs. See: ↓
		Open and close coupling	AR09.41-P-1311-01AL
15	Detach coolant hose (13) from circulation pump at fitting (10)	Installation:  Check hose clamp for tight seating; replace if necessary.
16	Remove coolant hose (12) at rear of radiator tank	Installation:  In order to avoid leaks on engine check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease, as well as observe exact seating of detent springs. See: ↓
		Open and close coupling	AR09.41-P-1311-01AL
17	Remove engine charge air channel upstream of charge air cooler	Installation:  In order to avoid leaks on engine check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease, as well as observe exact seating of detent springs. See: ↓	AR09.41-P-8623TI
		Open and close coupling	AR09.41-P-1311-01AL
18	Unclip charge air hose on engine charge air duct downstream of charge air cooler	Installation:  In order to avoid leaks on engine check sealing rings and detent springs for damage, thoroughly clean connecting points but do not grease, as well as observe exact seating of detent springs. See: ↓
		Open and close coupling	AR09.41-P-1311-01AL
19	Remove poly-V belt		AR13.22-P-1202TI
20	Disconnect engine wiring harness		AR01.00-P-2410TI
21	Unscrew bolt (14) of AC line at oil filter housing	Bolt, refrigerant line to engine	*BA83.55-P-1006-01A
22.1	Disconnect lines at separation point (3) from automatic transmission oil cooler	Transmission 722.9
23	Remove fuel lines (6) at fuel pipes	Mark fuel lines (6) to avoid problems when starting engine. Seal connections.
		Clamping device	Fig 6
		Set of stop plugs Installation:  Replace hose clamps to prevent leaks.	Fig 4
24	Drain/collect engine oil	Installation:  Replace sealing ring of oil drain screw.
		Oil drain screw to oil pan Engine 642 without particulate filter code 474	*BA01.45-P-1006-01Q
		Engine oil Engine 642 with particulate filter code 474	*BF18.00-P-1001-01A
		Engine oil	*BF18.00-P-1001-01S
25	Remove refrigerant compressor (A9)	For this purpose undo three bolts Mount refrigerant compressor (A9) with connected lines onto front axle carrier.
		Bolt on refrigerant compressor	*BA83.55-P-1005-01A
26	Remove bolts (2) on high pressure expanding hose (1)	Bolt, high-pressure expansion hose bracket to engine oil pan	*BA46.30-P-1005-01M
27.1	Disconnect catalytic converter hose clamp to diesel particulate filter	With code 474 Particulate filter
28.1	Completely remove diesel particulate filter bracket to transmission	With code 474 Particulate filter
29.1	Unhook shift rod (7a) at automatic transmission	Transmission 722.9 by detaching fuse (7). Secure shift rod (7a) to one side. Installation:  Replace both retainers (7).	AR27.60-P-0990T
29.2	Detach center shifter console and shift rod on transmission	Transmission 716.6
30.1	Support automatic transmission with assembly lift and transmission plate	Transmission 722.9 Transmission plate http://gotis.aftersales.mercedes-benz.com  Telescoping transmission jack 0.5 to 1.0 ton http://gotis.aftersales.mercedes-benz.com
30.2	Support transmission using transmission lift and transmission plate	Transmission 716.6 Transmission plate http://gotis.aftersales.mercedes-benz.com  Telescoping transmission jack 0.5 to 1.0 ton http://gotis.aftersales.mercedes-benz.com
31	Remove rear engine crossmember (8)	Also remove rear engine mount	AR22.10-P-1160TI
32	Disconnect front propeller shaft (9) from transmission		AR41.10-P-0050-02TI
	Connect front propeller shaft (9) to transmission		AR41.10-P-0050-07TI
		Self-locking nut, flexible coupling to transmission or front propeller shaft	*BA41.10-P-1001-01A
33	Screw on rear engine cross member (8)	Rear engine mount remains removed.
34	Take out assembly lift
35	Remove engine mount bolts (15)	Left and right side
		Bolt, front engine mount to front axle carrier	*BA22.10-P-1002-03A
36	Attach engine hoists to engine lifting eyes	Engine hoist (self-locking) carrying capacity 500 kg, chain length 1.3 m (recommended for passenger cars and off road vehicles) http://gotis.aftersales.daimlerchrysler.com
37	Remove engine	Ensure that engine does not rub against the hatched areas during removal or installation to avoid causing damage the engine or other components.
38	Install in the reverse order
39	Fill power steering pump and bleed		AR46.30-P-0010P
40	Bleed cooling system		AR20.00-P-1142-06TI
41	Inspect cooling system for leaks		AR20.00-P-1010TI
42	Check engine oil level		AR18.00-P-3035-01TI
43.1	Check transmission oil level and correct if necessary	Transmission 722.9	AR27.00-P-0270W
44	Check for leaks with engine running
45	Perform basic programming		AR00.19-P-0200T
46	Read out fault memory	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.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system

Fig 4: Identifying Set Of Stop Plugs (129 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying Hand Pump (210 589 00 71 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Clamping Device (000 589 40 37 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.