Removing and installing engine - AR01.10-P-2400CB

ENGINE 112 / (except 112.921 /941) in MODELS 210 / / /, 208, 202, 129 (except 210.081 /281 /082 /282) 

ENGINE 113 in MODELS 210, 208, 202, 129 

Shown on model 210 with engine 112 

Only models 208, 202 with engines 112, 113 

Shown on engine 112 

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform 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
		External torx set	Figure
		Torx bit set	Figure
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
1	Remove engine cover or air filter	The air filter is integrated into the engine cover in models 129, 202.093/033, 208.370/374/470 and 210.274/074 Remove engine trim panel or air filter by pulling it vertically up and off the cylinder head covers.
2	Inspect both rear engine lifting eyes for marking	Engine suspension fittings without codes must be replaced.)
	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	Installation:  After connecting ground lead, read fault memory and calibrate power windows. Vehicles with stationary heater: adjust time display on stationary heater.	AR54.10-P-0003A
	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 from radiator		AR20.00-P-1142HA
6	Drain and collect engine oil		*BA01.45-P-1003-01B
			*BF18.00-P-1001-01H
7	Detach connection hoses (23, 24) at oil lines (21, 22) and fit together with connection piece (25)	Seal connections!
		Set of plugs	Figure
	Connection fitting for automatic oil pipes		WF58.50-P-2020-01A
8	Remove viscous fan (1)	All except model 208.365/465 with engine 112. Right-hand thread!	AR20.40-P-5660C
9	Remove fan shroud (2).	On models fitted with suction fan, separate plug connection of suction fan before removing fan shroud.
10	Remove air filter housing (7).	All except model 129, 202.033/093, 208.370/374/470, 210.074/274
11	Remove resonance tube (8) and resonance unit (9)	All except model 129, 202.033/093, 208.370/374/470, 210.074/274 Separate plug connection of hot film mass air flow sensor (HFM-SFI) for this step and Unbolt resonance pipe at cylinder head cover. The resonance pipe is attached to the rear of the intake manifold with a plastic bracket. Do not damage plastic bracket.	AR07.07-P-1454A
12	Remove hot film mass air flow sensor with air intake pipe	Models 129, 202.033/093, 210.074/274, 208.370/374/470	AR07.07-P-1454AG
13	Detach coolant lines (18, 19) at coolant pump
14	Detach coolant line (20) at thermostat housing
15	Detach coolant line at top of expansion reservoir	Only for models 208, 202
16	Remove radiator	Models 210, 208, 202 with engine 113	AR20.20-P-3865HD
		Model 129 with engine 113	AR20.20-P-3865AV
17	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
18	Detach vacuum line (5) from brake booster at rear of intake manifold
19	Extract power steering pump (15) oil	Hand pump	*112589007200
20	Disconnect ground lead at power steering pump (15)
21	Detach return flow and pressure lines of power steering pump (15)	Seal connections!
		Set of plugs	Figure
			*BA46.30-P-1002-01A
			*BA46.30-P-1003-01A
22	Detach vacuum line (6) at intake manifold	Model 129 Detach vacuum line (6) directly at purge control valve.
	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. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
23	Disconnect fuel line (4) at fuel distributor	Release fuel pressure through service valve! Collect fuel.
		Engine 112	*BA07.52-P-1001-01A
		Engine 113	*BA07.52-P-1001-01A
		Pressure hose	Figure
24	Detach coolant line (17)	In model 202.093/033 an additional coolant line is attached to the right cylinder head. The coolant line at the right cylinder head leads to an external transmission oil cooler located on the right, behind the front apron. The routing of the coolant line to the left cylinder head is the same as that of production vehicles.
25	Disconnect engine wiring harness	Models 210, 208, 202	AR01.00-P-2410K
		Model 129	AR01.00-P-2410AV
26	Remove poly-V-belt (3)	Installation:  Lock tensioning device with a drift or pin (diameter 5 mm).
		Model 129, 210 with engine 113, 208 with engine 113, 202 with engine 113.	AR13.22-P-1202B
		Model 210 with engine 112, 208 with engine 112, 202 with engine 112. Installation:  Lock tensioning device with a drift or pin (diameter 5 mm).	AR13.22-P-1202BA
27	Disconnect connector from A/C compressor (16)
28	Unscrew A/C compressor (16) from timing case cover	Attach AC compressor at side in bottom of engine compartment with lines connected.
			*BA83.55-P-1001-01A
29	Detach exhaust system (10) at exhaust manifold	Installation:  In vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
			*BA14.10-P-1002-01B
30	Separate plug connections of sensors on right (G3/3x1) and on left (G3/4x1) and release	Only models 202, 208
31	Remove bracket (10a) of exhaust system	All except model 129 Support exhaust system. Installation:  Replace nuts
32	Unscrew clutch slave cylinder	Only model 210, 202, 129 with manual transmission. Do not disconnect line.	AR25.20-P-0150A
33	Take off propeller shaft (11) at transmission		*BA41.10-P-1001-01A
34	Release cable for parking shift lock (14)		AR27.60-P-0500-05B
35	Detach shift rod from transmission
36	Remove rear engine crossmember (11) at transmission	For this step support transmission.
			*BA22.10-P-1002-01L
			*BA22.10-P-1003-01L
37	Unscrew bolts (13) of front engine mounts at front axle carrier		*BA22.10-P-1001-01L
38	Press pressure line of level control out of fixtures at bottom part of oil pan	Model 129 only
39	Attach engine hoist to engine lifting eyes	On model 210 with engine 113 and model 208 with engines 112, 113 use the engine removal fixture	*WE58.40-Z-1012-11A
			*WE58.40-Z-1020-11A
40	Attach engine hoist to lifting eyes of engine
41	Install in the reverse order
42	Inspect cooling system for leaks	If fitting new cylinder head gaskets, bring engine to operating temperature beforehand.	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
43	Check oil level in automatic transmission and correct if necessary.		AR27.00-P-0101A
44	Run engine and inspect for leaks
45	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

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	Engines 113.940/941/ 942/943/944/ 945/946/960/ 961/962/963/ 965/967/968/ 969/980/981/ 982/984/986/ 992/995
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30	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 113.987	Engines 113.990/ 991	Engine 113.992/ 993/995	Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/988
BA07.52-P-1001-01A	Disconnect fuel feed line at fuel rail	Nm	38	38	38	38

Number	Designation		Engine 112 except 112.951/ 976	Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/993/ 995
BA14.10-P-1002-01B	Flange connection, exhaust manifold and front exhaust pipes	Nm	20	20

Number	Designation		Engines 112.910/920, 113.944 in models 202.026/029/033 /086/089/093	Engines 112.911/914/921/941, 113.940/980 in model 210.061/062/ 063/065/070/074/261/ 262/263/265/270/274
BA22.10-P-1001-01L	Bolt, front engine mounts to front axle carrier	Nm	35	35
BA22.10-P-1002-01L	Bolt, rear engine mount to rear engine crossmember	Nm	30	30
BA22.10-P-1003-01L	Bolt, rear engine crossmember to body	Nm	40	40

Number	Designation		Engines 112.921/941, 113.940 in model 210.081/ 082/083/281/ 282/283	Engine 112.923/943, 113.961 in model 129.059/ 064/068
BA22.10-P-1001-01L	Bolt, front engine mounts to front axle carrier	Nm	35	25
BA22.10-P-1002-01L	Bolt, rear engine mount to rear engine crossmember	Nm	35	30
BA22.10-P-1003-01L	Bolt, rear engine crossmember to body	Nm	40	40

Number	Designation		Engine 112.940, 113.943/984 in model 208.365/ 370/374/465/470
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	30
BA22.10-P-1003-01L	Bolt, rear engine crossmember to body	Nm	40

Number	Designation			Model 129	Model 202
BA41.10-P-1001-01A	Self-locking nut of flexible joint to transmission or front propeller shaft	M10	Nm	40	40
		M12	Nm	60	60

Number	Designation			Model 208	Model 210
BA41.10-P-1001-01A	Self-locking nut of flexible joint to transmission or front propeller shaft	M10	Nm	40	40
		M12	Nm	60	60

Number	Designation			Model 202.026/029/ 033/086/089/093	Model 208.365/370 374/465/470
BA46.30-P-1002-01A	Return line to power steering pump		Nm	2	2
BA46.30-P-1003-01A	High-pressure expansion hose to power steering pump	M14x1.5	Nm	30	-
		M16x1.5	Nm	40	40

Number	Designation			Models 210.061/063/ 065/070/074/ 081/082/083/ 261/263/265/ 270/274/281/ 282/283/ 663	Model 129.058/ 060/061/063/ 066/067/076
BA46.30-P-1002-01A	Return line to power steering pump		Nm	2	40
BA46.30-P-1003-01A	High-pressure expansion hose to power steering pump	M14x1.5	Nm	-	-
		M16x1.5	Nm	45	45

Number	Designation		Engines 112.923/943, 113.961 in model 129	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	20

Number	Designation			Engine 112 except 112.916/953/975	Engines 113.940/941/ 942/943/960/ 961/962/969/ 982	Engine 113.944/ 944980/984 /984/ 986/991
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	8.0	8.0	7.5
		Filling capacity without oil filter	Liters	7.5	-	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A	-
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A	-
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A	BB00.40-P-0229-05A

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

WE58.40-Z-1012-11A	Load regulator (engine hoist), self-locking
WE58.40-Z-1020-11A	Removal fixture for engine