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

ENGINE 112 in MODELS 203.081 /084 /281 /284 

Fig 1: Identifying Engine Remove/Install Components - Engine 112 In Models 203.081 /084 /281 /284 (1 Of 3)

Fig 2: Identifying Engine Remove/Install Components - Engine 112 In Models 203.081 /084 /281 /284 (2 Of 3)

Fig 3: Identifying Engine Remove/Install Components - Engine 112 In Models 203.081 /084 /281 /284 (3 Of 3)

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of lifting platform and position four support plates at lifting platform 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 running engine	Secure vehicle to prevent it starting off by itself. Wear closed and snug-fitting work clothes. Do not grasp 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 leadacid 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 cable		AR54.10-P-0003P
	Notes on battery	All models	AH54.10-P-0001-01A
2	Remove engine suction fan ducts (1) in front of air filter
3	Detach air filter housing (2) vertically toward top from cylinder head cover	Installation:  Slightly moisten retaining rubbers on cylinder head covers with antifriction agent and sealing ring for hot film mass air flow sensor (B2/5) in the air filter housing (2).
		Lubricant	*BR00.45-Z-1002-06A
4	Reduce fuel pressure via service valve (4)	Collect fuel
		Pressure hose	Figure
5	Dismount fuel line (5) at fuel distributor	Collect fuel
		Disconnect fuel feed line at fuel distributor	*BA07.52-P-1001-01A
6	Remove hot film mass air flow sensor (B2/5)		AR07.07-P-1454SV
7	Remove vacuum line (6) of purge valve
8	Pull out engine ventilation hose (7) from distributor unit vacuum line of brake booster
9	Remove vacuum line (8) of brake booster at connection (9) of intake manifold	To do so, press together both clamps (arrows) and pull out vacuum line (8).
10	Disconnect vacuum line (10) at rear of intake manifold
11.1	Dismount both brackets of oil line level control at timing case	Only for level control on the rear axle, code 480
12	Remove electric fan (11)		AR20.40-P-5000PV
13	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
14	Remove poly-V belt (12)		AR13.22-P-1202PV
15	Disconnect engine wiring harness	Guide plug for automatic transmission via propeller shaft for front axle gear.	AR01.00-P-2410PV
16	Extract oil from expansion reservoir of power steering pump	Hand pump	Figure
17.1	Remove return flow line at power steering pump	Model 203.281/284 with level control on rear axle code 480	AR46.30-P-0500PV
17.2	Remove return flow line at power steering pump	Only for level control on the rear axle, code 480	AR46.30-P-0500P
18.1	Remove high-pressure expansion hose on power steering pump	Model 203.281/284 with level control on rear axle code 480	AR46.30-P-0500PV
18.2	Remove high-pressure expansion hose on power steering pump	Only for level control on the rear axle, code 480	AR46.30-P-0500P
19.1	Remove ground line on power steering pump	Model 203.281/284 with level control on rear axle code 480	AR46.30-P-0500PV
19.2	Remove ground line on power steering pump	Only for level control on the rear axle, code 480	AR46.30-P-0500P
20	Take off front engine compartment panel	Lower engine compartment paneling.	AR61.20-P-1105P
21	Take off rear engine compartment panel	Lower engine compartment paneling.	AR61.20-P-1105P
	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
22	Drain coolant from radiator		AR20.00-P-1142PV
	Notes on coolant	All engines	AH20.00-N-2080-01A
23	Drain and collect engine oil	Installation:  Replace sealing ring of the oil drain screw.
		Oil drain plug to oil pan	*BA01.45-P-1003-01B
			*BF18.00-P-1001-01H
24	Remove left front axle shaft		AR33.30-P-0620P
25	Remove right front axle shaft		AR33.30-P-0620P
26.1	Separate connector (13) of refrigerant compressor (A9)	Vehicles with automatic air conditioning, code 580
27.1	Dismount refrigerant compressor (A9)	Vehicles with automatic air conditioning, code 580 Attach refrigerant compressor (A9) with connected lines to front axle carrier.
		Screw for AC compressor on mount	*BA83.55-P-1001-01F
28	Remove supporting clamp (15) for engine support and on oil pan top section	Support clamp to left engine support and oil pan upper section	*BA22.10-P-1008-01R
29	Detach bracket (16) of O2 sensor connectors at bottom of oil pan.	Firmly connect bracket (16) to transmission bell.
30	Detach transmission ground (W49) from transfer case
31	Remove the exhaust system (18) complete		AR49.10-P-7000PV
32	Dismount exhaust shielding plate (19) for propeller shaft front axle gear	Collared bolt for mounting carrier for front axle final drive and engine mount carrier	*BA33.30-P-1001-03D
33	Remove fuse (20a)
34	Unhinge shift rod (20) at floor shift of automatic transmission and attach to the side
35	Remove high-pressure line bracket of rack-and-pinion line at oil pan	Bolt, oil pan bottom section to oil pan top section	*BA01.45-P-1005-01B
36	Remove exhaust shielding plate (21) for rear engine mount	Remove at crossbrace.
37	Support automatic transmission with assembly lift and transmission platform	Transmission platform	*WE58.40-Z-1018-11A
38	Remove rear engine cross member (22)		AR22.10-P-1160PW
39	Remove rear engine mount		AR22.10-P-1160PW
40	Dismount front propeller shaft at transfer case	The flexible coupling remains on the propeller shaft.	AR41.10-P-0050-02EA
		Installation:  Mount front propeller shaft on the transfer case.	AR41.10-P-0050-07EA
		Self-locking nut, flexible coupling to transmission or front section of propeller shaft	*BA41.10-P-1001-01A
		Torque wrench	Fig 6
41	Loosen fitted sleeves of flexible coupling and push back propeller shaft		AR41.10-P-0050-09DA
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
42	Bolt, engine mount to rear engine crossmember (22)	Do not mount engine mount on transfer case.
43	Fasten the rear engine crossmember (22) with two bolts
44	Take out assembly lift
45	Unclip clip (23)	For attaching the oil lines for the automatic transmission.
46	Disconnect upper automatic transmission oil line (24) on radiator	Also detach circlip and close off connection. Installation:  Check O-ring and replace if necessary.
		Set of stop plugs	Figure
47	Disconnect lower automatic transmission oil line (25) on radiator	Also detach circlip and close off connection. Installation:  Check O-ring and replace if necessary.
		Set of stop plugs	Figure
48	Remove bracket (25a) on longitudinal member
49	Unclip bracket (25a) on radiator
50	Unclip lower automatic transmission oil line (25) for Automatic transmission on radiator
51	Remove coolant hose (26) between radiator and thermostat housing and place to the side	The coolant hose to the coolant expansion tank remains connected. Installation:  Check condition of hose clamp and coolant line (26), replace if necessary.
		6 mm socket hexagon on flexible shaft for hose clamps with worm drive	*WH58.30-Z-1001-06A
		7 mm socket hexagon on flexible shaft for hose clips with worm drive	*WH58.30-Z-1002-06A
52	Remove coolant hoses (27, 28) on coolant pump (29)	Installation:  Check condition of hose clamps and coolant hoses (27, 28), replace if necessary.
		6 mm socket hexagon on flexible shaft for hose clamps with worm drive	*WH58.30-Z-1001-06A
		7 mm socket hexagon on flexible shaft for hose clips with worm drive	*WH58.30-Z-1002-06A
53	Remove coolant hose (30) at rear of radiator tank	Do this by pressing the clamp together until it latches and pulling out the coolant line (30). Installation:  Check coolant hose (30); replace if necessary. Replace sealing ring from coolant hose (30).
54	Remove upper engine mount (31) from engine support (32)	Left-hand side.
		Bolt, front engine mount to engine support	*BA22.10-P-1004-01R
55	Remove upper engine mount (31) from engine support (32)	Right side.
		Bolt, front engine mount to engine support	*BA22.10-P-1004-01R
56	Hook engine hoists into the lifting eyes on the engine	Engine hoist (self-locking)	*WE58.40-Z-1012-11A
57	Check whether all lines and hoses etc. are removed
58	Pull engine forward, lower down to rear and lift a little toward front
59	Lift engine further and out
60	Install in the reverse order
61	Fill power steering pump and bleed	Model 203.081/084 without level control on rear axle code 480	AR46.30-P-0010P
		Model 203.281/284 with level control on rear axle code 480	AR46.30-P-0010PV
62	Bleed cooling system	Warm up the engine to normal operating temperature and fully open temperature regulator of heating (position "warm").
63	Inspect 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-1010P
64	Check engine oil level		AR18.00-P-3035-01PW
		Measuring rod	Fig 7
65	Check oil level in automatic transmission, correct if necessary		AR27.00-P-0101P
66	Check for leaks with engine running
67	Perform basic programming		AR00.19-P-0200P
68	Read out fault memory and erase	Stored faults which may be caused by removal, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system	*WH58.30-Z-1048-13A

OIL PAN

FUEL DISTRIBUTOR

ENGINE MOUNTS, ENGINE SUPPORTS

FRONT FINAL-DRIVE UNIT

PROPELLER SHAFT

REFRIGERANT COMPRESSOR

Engine lubrication

Fig 4: Identifying Pressure Hose (119 589 04 63 00)

Fig 5: Identifying Hand Pump (210 589 00 71 00)

Fig 6: Identifying Torque Wrench (001 589 66 21 00)

Fig 7: Identifying Measuring Rod (120 589 07 21 00)

Fig 8: Identifying Set Of Stop Plugs (129 589 00 91 00)