Remove/install electric fan - AR20.40-P-5000PV

ENGINE 112.912 in MODELS 203.061 /261, 209.361 /461 with TRANSMISSIONS 716.6, 722.6

ENGINE 112.946 in MODELS 203.064 /264 /764 with TRANSMISSION 722.6

ENGINE 112.961 in MODELS 203.065 /265 with TRANSMISSION 722.6

ENGINE 113.968 in MODELS 209.375 /475 with TRANSMISSION 722.6

ENGINE 113.987 in MODELS 209.376 /476 with TRANSMISSION 722.636

ENGINE 112.955 in MODELS 209.365 /465 with TRANSMISSION 722.618

ENGINE 112.916 in MODELS 203.081 /281

ENGINE 112.953 in MODELS 203.084 /284

Fig 1: Identifying Electric Fan Removal/Install Components - Engines 112.912, 112.946, 112.961, 112.916 & 112.953 (1 Of 2)

Fig 2: Identifying Electric Fan Removal/Install Components - Engines 112.912, 112.946, 112.961, 112.916 & 112.953 (2 Of 2)

Model 203 with 4MATIC

Fig 3: Identifying Electric Fan Removal/Install Components - Model 203 With 4Matic

MODIFICATION NOTES

16.5.06

"Disconnect/connect ground line on battery" removed

	Remove/install
1	Remove engine suction fan ducts (1) upstream of air filter housing (2)
2	Unscrew bracket of oil line rack-and-pinion steering (20) at front end	Model 203 with 4MATIC
3	Unscrew bracket of oil line level control (21) at timing case	Model 203 with 4MATIC and level control
4	Disconnect connector (3) of the electric suction fan engine and AC with integrated control (M4/7)
5	Remove horn (4)	Unplug contact of audible warning device.
6	Unscrew bolts of steering oil cooler to front end crossmember (7)	Two bolts.
7	Detach hydraulic line of power steering (5) at front end crossmember (7)
8	Take off front end crossmember (7) at front crossmember.	Unscrew bolts (8).
9	Unscrew bolts (10) at front end crossmember (7) on right and left.
10	Detach hood cable (11)
11	Detach retaining clips (12) of air ducting
	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
12	Drain coolant	Model 209 with engine 113	AR20.00-P-1142PV
	Notes on coolant	All engines	AH20.00-N-2080-01A
13	Push coolant line (13) out of fixture
14	Remove cable ties at front end crossmember (7)
15	Disconnect plug connection of hood lock on right (15)
16	Remove front end crossmember (7) together with hood cables	If the rubber mounts (19) are firmly attached in the radiator, do not pull front end crossmember (7) upwards with force, but unscrew retaining pin (9) on right and left. Press together retaining bracket (14) of radiator on right and left, then unhook front end crossmember (7) and remove.
17	Detach top coolant line at radiator	Model 209 with engine 113
		Use a screwdriver to push back the clip until it latches.
		Installation: Replace O-ring of coolant line.
18	Press clamp (16) on right and left	At the same time take out electric suction fan engine and AC with integrated control (M4/7) toward top.
19	Take out electric suction fan engine and AC with integrated control (M4/7) toward top	Installation: Ensure that plates (17) of electric suction fan engine and AC with integrated control (M4/7) are seated in supports (18) of radiator on right and left.
20	Install in the reverse order
21	Carry out operational check of hood lock
22	Inspect gaps of hood	If required, adjust gap dimension. See: ↓
		Model 203.0	AR60.00-P-0700-01P *BE60.00-P-1001-01E
		Model 203.2	AR60.00-P-0700-01PA *BE60.00-P-1001-01E
		Model 203.7	AR60.00-P-0700-01PB *BE60.00-P-1001-01E
		Model 209.3	AR60.00-P-0700-01Q *BE60.00-P-1001-01G
		Model 209.4	AR60.00-P-0700-01QA *BE60.00-P-1001-01G
		Feeler gauge	Figure
23	Read out fault memory and erase	When the work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. The stored faults can be caused by removed cables during installation or test operations, as well as by simulation.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system

CHECK VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.004/006 / 007/008/016 / 018/020/035 / 040/042/043 / 045/046/052 / 056/061/064 / 065/081/084 / 085/087	Model 203.204/206/ 207/208/216/ 218/220/235/ 240/242/243/ 245/246/252/ 254/256/261/ 264/265/281/ 284/285/287/ 292
BE60.00-P-1001-01E	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (±1)	3.5 (±1)
		Engine hood to headlamp	Dimension "R"	mm	4 (-0.5/+1.5)	4 (-0.5/+1.5)
		Engine hood to bumper	Dimension "D"	mm	-	-
		Engine hood to bumper	See picture		AR60.00-P-0700-01P	AR60.00-P-0700-01PA

CHECK VALUES FOR GAP DIMENSIONS ON HOODS, DOORS AND LIDS

Number	Designation				Model 203.706/707/ 708/718/735/ 740/742/743/ 745/746/747/ 756/764
BE60.00-P-1001-01E	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.6 (±1)
		Engine hood to headlamp	Dimension "R"	mm	4 (±0.5)
		Engine hood to bumper	Dimension "D"	mm	5
		Engine hood to bumper	See picture		AR60.00-P-0700-01PB

TEST AND ADJUSTMENT VALUES FOR GAP DIMENSIONS

Number	Designation				Model 209.3	Model 209.4
BE60.00-P-1001-01G	Gap dimension	Engine hood to fender	Dimension "A"	mm	3.5 (± 0.5)	3 (± 1)
		Engine hood to headlamp	Dimension "B"	mm	3.5 (± 0.5)	4 (± 0.5)
		Engine hood to bumper	Dimension "C"	mm	4 (± 0.5)	5 (±0.5)
		Engine hood to bumper		See picture	AR60.00-P-0700-01Q	AR60.00-P-0700-01QA

Fig 4: Identifying Feeler Gauge (129 589 03 21 00)

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1048-13A	STAR DIAGNOSIS diagnosis system, Compact Passenger Car	6511 1801 00