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

ENGINE 112.917 in MODELS 211.080 /280 

ENGINE 112.954 in MODEL 211.082 /282 

ENGINE 112.975 in MODEL 220.087 /187 

ENGINE 113.948 in MODEL 220.083 /183 

ENGINE 113.966 in MODEL 220.084 /184 

ENGINE 113.969 in MODEL 211.083 /283 

Shown on model 220 with engine 113 

Shown on model 220 with engine 113 

18.4.06

Banjo bolt, high pressure expansion hose to power steering pump

Model 211 with engine 112, 113

*BA46.30-P-1002-01M

	Remove/install
	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 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
	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 from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
	Notes on self-locking nuts and bolts	All models	AH00.00-N-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 goggles. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground line
	Notes on battery	All models	AH54.10-P-0001-01A
		Model 220	AR54.10-P-0003I
		Model 211.0	AR54.10-P-0003T
		Model 211.2	AR54.10-P-0003TA
2	Remove lower engine compartment paneling	Model 220	AR61.20-P-1105M
		Model 211	AR61.20-P-1105T
	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
3	Drain coolant at radiator		AR20.00-P-1142HA
	Notes on coolant	All engines	AH20.00-N-2080-01A
4	Drain and collect engine oil	Installation:  Replace sealing ring of oil drain screw.
		Oil drain screw to oil pan	*BA01.45-P-1003-01B
			*BF18.00-P-1001-01H
5	Remove engine suction fan ducts (1) in front of air filter
6	Remove engine front cover (2) in front of air filter
7	Remove air filter housing (3).
8	Inspect both rear engine lifting eyes for marking
	Rear lifting eyes of engine reinforced		BT01.00-P-0001-01A
9.1	Detach coolant hose (4) on coolant expansion reservoir	Model 220 Installation:  Check condition of hose clamps and coolant hose (4); replace if necessary.
9.2	Detach coolant hose (4) between expansion reservoir and radiator	Model 211
10	Remove coolant hose (5) between thermostat housing and radiator	Installation:  Check hose clamps, coolant hose (5) and O-ring in connection fitting to radiator for condition; replace if necessary.
11	Remove fan shroud with electric fan (6)	Model 220	AR20.40-P-6800AB
		Model 211	AR20.40-P-6800TB
12	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
13	Dismount coolant hoses (7, 8) at coolant pump	Installation:  Check condition of hose clamps and coolant hoses (7, 8), replace if necessary.
14	Remove poly-V belt (9)	Installation:  Block tensioning device with a 5 mm punch or pin.
		Model 220	AR13.22-P-1202BA
		Model 211	AR13.22-P-1202PV
15	Release fuel pressure from service-valve (10)	Collect fuel.
		Pressure hose	Fig 3
16	Remove hot film mass air flow sensor (B2/5)	Model 220	AR07.07-P-1454AA
		Model 211	AR07.07-P-1454SV
17.1	Detach the vacuum line of brake booster (11) from the intake manifold and from vacuum line brake booster (12)	Model 220 only Press two locks together and detach vacuum line for brake booster (11) from intake manifold, or vacuum line of brake booster (12) from vacuum line for brake booster (11).
18.1	Detach vacuum hose for purge control valve (13) from rear of intake manifold	Model 220
18.2	Detach vacuum hose for purge control valve (13) from front of intake manifold	Model 211
19	Detach heater hose (14) from rear of splash wall	Installation:  Check hose clamps and heater hose (14) for condition and replace if necessary.
20	Dismount fuel line (15) at fuel distributor	Open the fuel tank cap before detaching.
		Disconnect fuel feed line at fuel distributor	*BA07.52-P-1001-01A
21	Suction off oil from reservoir of power steering pump (16)	Hand pump	Figure
22	Detach return line (17) from fluid reservoir of power steering pump (16)	Seal the connections.
23.1	Detach high pressure expansion hose (18) from power steering pump	Model 220 Seal the connections. Installation:  Replace sealing rings.
		Banjo bolt, high pressure expansion hose to power steering pump	*BA46.30-P-1016-01C
23.2	Detach high pressure expansion hose (18) from power steering pump	Model 211 Installation:  Replace sealing rings.
		Banjo bolt, high pressure expansion hose to power steering pump	*BA46.30-P-1002-01M
24	Detach ground cable (19) on power steering pump
25	Disconnect engine wiring harness	Model 220	AR01.00-P-2410M
		Model 211	AR01.00-P-2410TC
26.1	Detach right side oil line (22) of automatic transmission from the radiator	Model 220 Seal off openings.
		Union nut, automatic transmission ATF line to radiator	*BA20.20-P-1001-01A
		Set of stop plugs	Fig 6
27.1	Detach left side oil line (23) for automatic transmission from left side separation point under radiator	Model 220 Seal off openings.
		Set of stop plugs	Fig 6
28	Detach high-pressure line (24) of rack-and-pinion steering in the area of oil pan bottom section (25)	Model 220
		Bolt, oil pan bottom section to oil pan top section Model 211	*BA01.45-P-1005-01B
		Bolt, high-pressure expansion hose bracket to engine oil pan	*BA46.30-P-1005-01M
29.1	Unscrew the two screws for automatic transmission oil line at oil pan	Model 211
30	Detach connector (26) from refrigerant compressor (A9)
31	Remove refrigerant compressor (A9)	Attach refrigerant compressor (A9) to bottom of engine compartment with lines connected.
32	Remove exhaust system (27) complete	Model 220 Installation:  On vehicles with engine damage, the exhaust system must be examined for swarf before assembling and any swarf present must be removed, in order to avoid consequential damage to the catalytic converter system.	AR49.10-P-7000AA
		Model 211 Installation:  On vehicles with engine damage, the exhaust system must be examined for swarf before assembling and any swarf present must be removed, in order to avoid consequential damage to the catalytic converter system.	AR49.10-P-7000TB
33.1	Remove exhaust bracket (28) from the transmission	Model 220
34	Remove shift rod for automatic transmission	To do this, press the locking device upwards till the shift rod bolt can be extended.
35	Detach right mounting bracket from engine compartment paneling	The mounting bracket is located beside the automatic transmission.
36	Remove left and right front axle shaft		AR33.30-P-0620I
37.1	Detach exhaust shielding plate (29) for front propeller shaft	Model 220 Detach behind the transfer case. Remove exhaust shielding plate (29) over the right exhaust pipe.
38.1	Detach heat shield	Model 211 Detach on connecting member for front axle gear and at engine mount at the rear.
39.1	Detach electrical coupling with bayonet lock on transmission	Model 211
40.1	Disconnect ground cable on starter	Model 211
41.1	Detach ground cable on transfer case	Model 220
41.2	Detach ground cable on automatic transmission	Model 211
42	Dismount front propeller shaft at transfer case	The flexible coupling remains on the propeller shaft.
		Installation:  Mount front propeller shaft at transfer case	AR41.10-P-0050-07I
		Self-locking nut, flexible coupling to transmission or front section of propeller shaft	*BA41.10-P-1001-01A
43	Loosen fitted sleeves of flexible coupling and push back propeller shaft	Model 220	AR41.10-P-0050-09I
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
		Model 211	AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
44	Support automatic transmission with assembly lift and transmission platform
45	Remove rear engine crossmember (30) and rear engine mount	Model 220	AR22.10-P-1160IW
		Model 211	AR22.10-P-1160TW
46	Fasten the rear engine crossmember (30) with two bolts	Do not install the engine mounts.
47	Take out assembly lift
48	Dismount top left and right engine mount (20) from engine support (21)	Bolt, front engine mount to engine support	*BA22.10-P-1004-01L
49	Hook engine hoist into the lifting eyes on the engine
50	Check whether all lines and hoses etc. are removed
51	Adjust engine position	Pull engine forward, lower down to rear and lift a little toward front. Ensure that rear of engine does not touch the firewall.
52	Lift engine further and out
53	Install in the reverse order
54	Fill power steering pump and bleed	Model 220 except Active Body Control (ABC) code 487	AR46.30-P-0010B
		Model 211	AR46.30-P-0010P
55	Bleed cooling system	Warm up the engine to normal operating temperature and set the temperature control of heating to warm.
56	Inspecting cooling system for leaks	If fitting new cylinder head gaskets, bring engine to operating temperature beforehand. Otherwise the complete filling of the engine with coolant is not guaranteed.	AR20.00-P-1010HA
57	Check engine oil level	Model 211 with engine 113.969 Model 220 with engine 113.948/966	AR18.00-P-3035-01IW
		Model 211 with engine 112.917/954 Model 220 with engine 112.975	AR18.00-P-3035-01BM
			*BF18.00-P-1001-01H
		Dipstick	Fig 5
58	Check oil level in automatic transmission, correct if necessary		AR27.00-P-0100AC
59	Check for leaks with engine running
60	Perform basic programming	Model 220	AR00.19-P-0200M
		Model 211	AR00.19-P-0200T
61	Read out fault memory and erase	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

Number	Designation			Engine 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	Engine 113.940/941/ 942/943/944/ 945/946/960/ 961/962/963/ 965/967/968/ 969/980/981/ 982/984/986/ 992/995	Engine 112.916/953/975, 113.948/966
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30	30	30
BA01.45-P-1005-01B	Oil pan bottom section bolt at oil pan upper section	Thread not pre-tapped	Nm	-	-	14
		Thread pre-tapped	Nm	-	-	9

Number	Designation		Engine 112 except 112.945/951/960/961
BA07.52-P-1001-01A	Fuel feed line to fuel distributor	Nm	38

Number	Designation		Engine 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	Fuel feed line to fuel distributor	Nm	38

Number	Designation		Engine 112 except 112.942/970, engines 113.940/941/943/944/945/946/948/960/961/962/963/966/967/968/969/980/982/984/986/992/993/995
BA20.20-P-1001-01A	Union nut, automatic transmission oil line to radiator	Nm	20

Number	Designation		Engine 112.975, 113.948/966 in model 220
BA22.10-P-1004-01L	Bolt, front engine mount to engine support	Nm	50

Number	Designation		Engine 113.969 in model 211	Engine 112.917/954 in model 211
BA22.10-P-1004-01L	Bolt, front engine mount to engine support	Nm	50	50

Number	Designation			Model 220	Model 211
BA41.10-P-1001-01A	Self-locking nut, flexible coupling to transmission or front propeller shaft	M10	Nm	-	40
		M12	Nm	60	60

Number	Designation		Model 220.083/084/087/183/184/187
BA46.30-P-1016-01C	Banjo bolt, high pressure expansion hose to power steering pump	Nm	45

Number	Designation		Model 211 with engine 112, 113
BA46.30-P-1002-01M	Banjo bolt, high pressure expansion hose to power steering pump	Nm	45
BA46.30-P-1005-01M	Bolt, bracket for high pressure expansion hose to engine oil pan	Nm	10

Number	Designation			Engine 112 except 112.916/953/975	Engine 112.975	Engine 113.948/966
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	8.0	8.0	8.0
		Filling capacity without oil filter	Liters	7.5	7.5	7.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A	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			Engine 113.940/941/942/943/960/961/962/967/969/982
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	8.0
		Filling capacity without oil filter	Liters	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A