AR01.10-P-2401QB Remove/install engine with transmission 18.5.

09
ENGINES 272.920 in MODEL 203.052 /252 /752
ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454
ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456
ENGINES 273 in MODEL 209

P01.10-2764-09

1 Vacuum line 4 Power steering return line 15 Coolant hose

2 Crankcase ventilation system vacuum 5 High pressure expansion hose 16 Automatic transmission oil line
line 6 Banjo bolt 17 Coolant hose
3 Power steering expansion reservoir 10 Radiator 18 Coolant hose
19 Fuel pipe

P01.10-2765-09

5 High pressure expansion hose 10 Radiator 13 Range selector lever

7 Screw 11 Retaining clip 14 Clutch operation hydraulic line
9 Automatic transmission oil line 12 Shift rod

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 1 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
 P01.10-2766-07

8 Bolt A9 Refrigerant compressor A9x1 Refrigerant compressor connector

20 Bolt

P01.10-2848-08

4a Power steering feed line 15 Coolant hose 16 Automatic transmission oil line
9 Automatic transmission oil line 15a Coolant hose 21 Separation point

Modification notes
2.6.08 Installation note for replacing sealing rings of the Step 20.2
automatic transmission oil lines - added

Remove/install
Danger! Risk of death caused by vehicle slipping or Align vehicle between columns of vehicle lift AS00.00-Z-0010-01A
toppling off the lifting platform. and position four support plates at vehicle lift
support points specified by vehicle
manufacturer.
Danger! Risk of explosion caused by fuel igniting, No fire, sparks, open flames or smoking. AS47.00-Z-0001-01A
risk of poisoning caused by inhaling and Only pour fuels into suitable and
swallowing fuel and risk of injury to eyes appropriately marked containers.
and skin caused by contact with fuel Wear protective clothing when handling fuel.
Danger! Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A
scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly
Risk of poisoning caused by swallowing and release the pressure. Do not pour
coolant. coolant into beverage containers.
Wear protective gloves, protective clothing
and safety glasses.
1 Disconnect ground line from battery Model 203 AR54.10-P-0003P
Model 209 AR54.10-P-0003Q
Notes on battery AH54.10-P-0001-01A
2 Remove air filter housing AR09.10-P-1150QB
3 Remove hot film mass air flow sensor AR07.07-P-1453QB
4 Remove air duct housing AR09.20-P-0080QB
5 Unclip vacuum line (1) and detach from
vacuum line (2)
6 Disconnect brake booster vacuum line on
intake manifold
7 Remove electric fan AR20.40-P-5000QB
8 Attach guard plate for radiator/condenser

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 2 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
 Guard plate for radiator/condenser WF58.50-P-0110-01A
9 Remove poly-V belt AR13.22-P-1202QB
10 Suction off oil from expansion reservoir (3) *210589007100
11 Detach feed line (4a) from power steering Engine 273
pump
*003589033700
12 Detach return line (4) from expansion Engine 272
reservoir (3)
*BA46.30-P-1004-01K
13 Detach high-pressure expansion hose (5) Installation: Replace sealing ring.
from power steering pump by unscrewing the
banjo bolt (6)
*BA46.30-P-1006-01K
14 Raise vehicle with vehicle lift AR00.60-P-1000P
15 Detach lower engine compartment paneling AR61.20-P-1105P
16 Drain coolant at radiator AR20.00-P-1142QB
Notes on coolant AH20.00-N-2080-01A
17 Drain engine oil
Engine oil and filter change Model 203, 209 with engine 272 AP18.00-P-0101PIT
Model 209 with engine 273 AP18.00-P-0101RX
18 Detach high-pressure expansion hose (5) Engine 272
from oil pan by unscrewing bolt (7)
*BA46.30-P-1009-01K
19 Remove coolant compressor (A9) from Disconnect refrigerant compressor
timing case cover and engine support; to do connector (A9x1) and attach refrigerant
this unscrew the bolts (8) compressor (A9) with connected pipe
system, laterally at bottom of engine
compartment.
*BA83.55-P-1001-01M
20.1 Detach oil lines (9, 16) from cooler (10) Engine 272 with transmission 722.9
Seal connections; otherwise, the
automatic transmission can get damaged
due to contamination.
*129589009100
Installation: Replace sealing rings. Pay
attention to correct assembly of oil lines (9,
16) on cooler (10).
20.2 Disconnect oil lines (9, 16) to separation Engine 273 with transmission 722.9
points (21)
Seal connections; otherwise, the
automatic transmission can get damaged
due to contamination.
Installation: Replace sealing rings. Pay
attention to correct assembly of oil lines (9,
16) at the connecting points (21).
*BA27.55-P-1001-01D
*129589009100
21.1 Remove retaining clip (11) and detach shift Transmission 722.9
rod (12) on range selector lever (13)
Installation: Replace retaining clip (11).
21.2 Detach center shifter console and shift rod Transmission 716.6 AR26.60-P-0600-02V
on transmission
22 Support transmission with transmission jack Passenger car transmission platform
and transmission plate http://gotis.aftersales.mercedes-benz.com
Transmission jack
http://gotis.aftersales.mercedes-benz.com
23 Remove rear engine mount AR22.10-P-1160QB
24 Remove rear engine crossmember Engine 273
To detach propeller shaft bolts.
*BA22.10-P-1005-03B
25 Remove propeller shaft from drive flange of AR41.10-P-0050-02EA
transmission
Installation: Mount front propeller shaft AR41.10-P-0050-07EA
on transmission
*BA41.10-P-1001-01A
*001589662100
26 Install rear engine crossmember Engine 273
*BA22.10-P-1005-03B

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 3 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
27 Lower telescopic lifter and allow
transmission to lie on the rear engine
crossmember
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
28 Separate hydraulic line (14) Transmission 716.6
Seal the connections.
*BA25.20-P-1002-01B
*129589009100
Brake fluid notes AH42.50-P-0001-01A
29 Remove engine wiring harness to remove AR01.00-P-2410-02QB
engine
30 Remove catalytic converters AR49.10-P-5531QB
31 Detach coolant hoses (15, 15a, 17, 18) Check coolant hoses (15, 15a, 17, 18) for
condition, replace if necessary.
32 Remove oil dipstick guide tube AR18.40-P-3510QB
33 Release fuel pressure through service valve AR07.03-P-1460-01VA
*BA07.03-P-1004-01B
*119589046300
34 Remove fuel line (19) from fuel distributor Seal connections.
*BA07.03-P-1001-01B
*129589009100
35 Disconnect engine mount from front axle Model 203 *BA22.10-P-1001-01S
carrier; to do this unscrew bolts (20)
Model 209 *BA22.10-P-1002-03B
36 Lift out engine together with transmission When lifting out engine ensure that
steering coupling and refrigerant compressor
(A9) are not damaged, no cables and lines
are damaged and engine does not touch the
partition wall.
Slightly raise engine equally at front and
back, pull slightly forward, then lower back
and lift out.
37 Install in the reverse order
38 Bleed clutch operating system Transmission 716.6 AR25.20-P-0070P
39.1 Check oil level in manual transmission and Transmission 716.6
correct if necessary
Correct oil level = 10 mm below the
bottom edge of the filler opening. Carry out
measurement e. g. with a slanted hexagon
socket wrench.
*BA26.40-P-1003-01C
*BA26.40-P-1004-01C
39.2 Check oil level in automatic transmission Transmission 722.9 AR27.00-P-0270W
and correct if necessary
40 Fill power steering pump and bleed Vehicles with code (480) Level control at rear AR32.30-P-0630A
axle
Vehicles without rear axle level control AR46.30-P-0010P
system
Danger! Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A
off by itself when engine is running. Risk of itself.
injury caused by contusions and burns Wear closed and snug-fitting work clothes.
during starting procedure or when working Do not touch hot or rotating parts.
near the engine as it is running
41 Carry out engine test run Check bolted connection of fuel line (19),
connectors of oil lines (9, 16), high pressure
expansion hose (5), return line (4),
connectors of coolant hoses (15, 15a, 17,
18), exhaust system and oil drain screw for
leaktightness.

Power steering pump

Number Designation Engine Engine

272 272, 273
in model in model
203 209
except
code 480

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 4 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
 BA46.30-P-1004-01K Hose clamp, hydraulic line to power steering Nm 3 3
pump expansion reservoir

BA46.30-P-1006-01K Banjo bolt, high pressure expansion hose to Nm 45 45

power steering pump

BA46.30-P-1009-01K Bolt, bracket for high pressure expansion hose to Nm 10 10

engine oil pan

Refrigerant compressor

Number Designation Engine Engine

272 273

BA83.55-P-1001-01M Bolt, refrigerant compressor to timing case/ Nm 20 20

crankcase/engine support

Clutch actuation

Number Designation Trans-

mission
716.6

BA25.20-P-1002-01B Union nut for line for clutch operating system to Nm 16

hose

Injectors, injection valves, lines

Number Designation Engine Engine

272 273

BA07.03-P-1001-01B Union nut, fuel line to fuel distributor Nm 20 20

BA07.03-P-1004-01B Protective cap on service valve Plastic Nm 2 -

Metal Nm 15 -

Engine suspension, engine mounts, engine supports

Number Designation Engine 272

in model 203
except 4-MATIC

BA22.10-P-1001-01S Bolt, front engine mount to front axle carrier Nm 35

Engine mount, engine support (engine side)

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 5 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
 Number Designation Model
209

BA22.10-P-1002-03B Bolt connecting front engine mount to front axle Nm 35

crossmember

BA22.10-P-1005-03B Bolt, rear engine support to frame floor assembly Nm 50

Housing

Number Designation Trans-

mission
716.6

BA26.40-P-1003-01C Oil filler plug Nm 35

BA26.40-P-1004-01C Oil drain screw Nm 30

Transmission oil cooling system

Number Designation Trans-

mission
722.9

BA27.55-P-1001-01D Union nut connecting transmission oil line Nm 25

to cooler

Propeller shaft

Number Designation Model Model

203 209

BA41.10-P-1001-01A Self-locking nut, flexible coupling to transmission M10 Nm 40 40

or front propeller shaft

M12 Nm 60 60

210 589 00 71 00 129 589 00 91 00 003 589 03 37 00 119 589 04 63 00

Hand pump Set of stop plugs Hose clamp pliers Pressure hose

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 6 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..
Special tools

001 589 66 21 00
Torque wrench

© Daimler AG, 1/4/11, G/07/10 / ar01.10-p-2401qb / Remove/install engine with transmission Page 7 of 7
ENGINES 272.920 in MODEL 203.052 /252 /752 ENGINES 272.940 in MODEL 203.054 /254, 209.354 /454 ENGINES 272.960 in MODEL 203.056 /256 /756, 209.356 /456 ENGINES 273 in ..