Removing and installing engine - AR01.10-P-2400C
ENGINE 112 in MODELS 210.081 /281 /082 /282
Shown on model 210.082 with engine 112
| Remove/install | |||
| Risk of death caused by vehicle slipping or toppling off the lifting platform. | Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. | AS00.00-Z-0010-01A | |
| Notes on self-locking nuts and bolts | AH00.00-N-0001-01A | ||
| Figure | |||
| Figure | |||
| *WH58.30-Z-1001-06A | |||
| *WH58.30-Z-1002-06A | |||
| 1 | Remove engine trim panel | ||
| 2 | Inspect both rear engine lifting eyes for marking | ||
| Rear lifting eyes of engine reinforced | Engine 112, 113 | BT01.00-P-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 safety glasses. Only pour battery acid into suitable and appropriately marked containers. | AS54.10-Z-0001-01A | |
| 3 | Disconnect battery ground cable | AR54.10-P-0003A | |
Vehicles with stationary heater: adjust time display on stationary heater. |
|||
| Notes on battery | MODEL all | AH54.10-P-0001-01A | |
| 4 | Remove engine compartment paneling | AR61.20-P-1105AB | |
| Risk of injury
to skin and eyes caused by 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 | |
| 5 | Drain coolant at radiator, pour in | AR20.00-P-1142HA | |
| 6 | Drain and collect engine oil | *BA01.45-P-1003-01B | |
| *BF18.00-P-1001-01H | |||
| 7 | Remove viscous fan (1) | AR20.40-P-5660C | |
| 8 | Remove fan shroud (2) |
|
|
| 9 | Attach guard plate for radiator / condenser | ||
| Guard plate for radiator / condenser | WF58.50-P-0110-01A | ||
| 10 | Remove air filter housing (7). | ||
| 11 | Remove resonance tube (8) and resonance unit (9) |
|
AR07.07-P-1454A |
The resonance pipe is attached to the rear of the intake manifold with a plastic bracket. |
|||
| 12 | Detach coolant line (18, 19) at coolant pump | ||
| 13 | Detach coolant line (20) at thermostat housing | ||
| 14 | Detach vacuum line (5) from brake booster at rear of intake manifold | ||
| 15 | Extract oil of power steering pump | Fig 6 | |
| 16 | Detach return flow and pressure line at power steering pump (15) | ||
| Fig 9 | |||
| *BA46.30-P-1002-01A | |||
| *BA46.30-P-1003-01A | |||
| 17 | Detach vacuum line (6) at intake manifold | ||
| Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to 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 | |
| 18 | Disconnect fuel line (4) at fuel distributor | Collect fuel. |
|
| *BA07.52-P-1001-01A | |||
| Figure | |||
| 19 | Detach coolant line (17) | ||
| 20 | Disconnect engine wiring harness | AR01.00-P-2410K | |
| 21 | Remove poly-V-belt (3) | AR13.22-P-1202B | |
| 22 | Detach connection hoses (23, 24) at oil lines (21, 22) and fit together with connection piece (25) | ||
| Fig 9 | |||
| Connection fitting for automatic oil pipes | WF58.50-P-2020-01A | ||
| 23 | Unscrew A/C compressor (16) from timing case cover | ||
| *BA83.55-P-1001-01A | |||
| 24 | Detach exhaust system (10) at exhaust manifold | ||
| *BA14.10-P-1002-01B | |||
| 25 | Remove bracket (10a) of exhaust system | Support exhaust system for this step. |
|
| 26 | Detach vibration damper at transmission below propeller shaft | ||
| 27 | Take off propeller shaft (11) at transmission | *BA41.10-P-1001-01A | |
| 28 | Release cable for parking shift lock (14) | AR27.60-P-0500-05B | |
| 29 | Detach shift rod from transmission | ||
| 30 | Take off front wheels | ||
| 31 | Remove drive shafts (26) | AR33.30-P-0620A | |
| 32 | Remove engine crossmember (12) | ||
| *BA22.10-P-1003-01L | |||
| *BA22.10-P-1002-01L | |||
| 33 | Unscrew bolts (13) of front engine mounts at front axle carrier. | *BA22.10-P-1001-01L | |
| 34 | Disconnect connector from A/C compressor (16) | ||
| 35 | Disconnect ground lead at power steering pump (15) | ||
| 36 | Attach engine hoist to engine lifting eyes | *WE58.40-Z-1012-11A | |
| 37 | Attach engine hoist to lifting eyes of engine | ||
| 38 | Install in the reverse order | ||
| 39 | Inspect cooling system for leaks | AR20.00-P-1010HA | |
| 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 running engine | Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts. |
AS00.00-Z-0005-01A | |
| 40 | Check oil level in automatic transmission and correct if necessary. | AR27.00-P-0101A | |
| 41 | Run engine and inspect for leaks | ||
| 42 | Read out fault memory and erase | Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work: ↓ Diagnosis Manual Volume 2, Index 0: Connection and use of test equipment |
|
| 43 | Check chassis alignment and adjust if necessary | AR40.20-P-0322E |
| Number | Designation | Engines 112.910/911/ 912/913/914/ 915/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 951/954/955/ 960/961/970/ 972/973/976 | ||
|---|---|---|---|---|
| BA01.45-P-1003-01B | Oil drain screw on oil pan | M14 | Nm | 30 |
| Number | Designation | Engine 112 except 112.945/951/ 960/961 | |
|---|---|---|---|
| BA07.52-P-1001-01A | Disconnect fuel feed line at fuel rail | Nm | 38 |
| Number | Designation | Engine 112 except 112.951/ 976 | |
|---|---|---|---|
| BA14.10-P-1002-01B | Flange connection, exhaust manifold and front exhaust pipes | Nm | 20 |
| Number | Designation | Engines 112.921/941, 113.940 in model 210.081/ 082/083/281/ 282/283 | |
|---|---|---|---|
| BA22.10-P-1001-01L | Bolt, front engine mounts to front axle carrier | Nm | 35 |
| BA22.10-P-1002-01L | Bolt, rear engine mount to rear engine crossmember | Nm | 35 |
| BA22.10-P-1003-01L | Bolt, rear engine crossmember to body | Nm | 40 |
| Number | Designation | Model 210 | ||
|---|---|---|---|---|
| BA41.10-P-1001-01A | Self-locking nut, flexible joint to transmission or front propeller shaft | M10 | Nm | 40 |
| M12 | Nm | 60 | ||
| Number | Designation | Models 210.061/063/ 065/070/074/08 1/082/083/261/ 263/265/270/274/281/282/283/ 663 | ||
|---|---|---|---|---|
| BA46.30-P-1002-01A | Return line to power steering pump | Nm | 2 | |
| BA46.30-P-1003-01A | High-pressure expansion hose to power steering pump | M14x1.5 | Nm | - |
| M16x1.5 | Nm | 45 | ||
| Number | Designation | Engines 112.910/911/ 920/921/940/941, 113.940/943/944/980 /984 in models 202, 208, 210 | |
|---|---|---|---|
| BA83.55-P-1001-01A | Bolt, refrigerant compressor to bracket | Nm | 20 |
| Number | Designation | Engine 112 except 112.916/953/975 | ||
|---|---|---|---|---|
| BF18.00-P-1001-01H | Engine oil | Filling capacity with oil filter | Liters | 8.0 |
| Filling capacity without oil filter | Liters | 7.5 | ||
| Specifications for Operating Fluids | Sheet | BB00.40-P-0229-01A | ||
| Sheet | BB00.40-P-0229-03A | |||
| Sheet | BB00.40-P-0229-05A | |||
Commercially available tools
| Number | Designation |
|---|---|
| WH58.30-Z-1001-06A | 6 mm socket hexagon on flexible shaft for hose clamps with worm drive |
| WH58.30-Z-1002-06A | 7 mm socket hexagon on flexible shaft for hose clamps with worm drive |
Workshop equipment
| WE58.40-Z-1012-11A | Load regulator (engine hoist), self-locking |