Remove, install engine - AR01.10-P-2400PK

ENGINE 111.955 in MODEL 203.045 /245 /745 with TRANSMISSION 722.6

ENGINE 111.951 in MODEL 203.035 /235 /735 with TRANSMISSION 722.6

Shown on engine 111.955

Fig 1: Identifying Engine Remove/Install Components - Shown On Engine 111.955 With Transmission 722.6 (1 Of 3)

Fig 2: Identifying Engine Remove/Install Components - Shown On Engine 111.955 With Transmission 722.6 (2 Of 3)

Fig 3: Identifying Engine Remove/Install Components - Shown On Engine 111.955 With Transmission 722.6 (3 Of 3)

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of 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
	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 safety glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground cable	Do not attach quiescent current retention unit.	AR54.10-P-0003P
	Notes on battery	All models	AH54.10-P-0001-01A
2	Remove top engine covers (1)	Installation: Moisten retaining rubber of engine covers (left) with sliding compound.
3.1	Remove air filter housing (2) with air recirculation flap actuator (3)	Engine 111.955.
		Remove air filter housing.	AR09.10-P-1150PK
		Remove air recirculation flap actuator with resonance body	AR09.50-P-8842PK
3.2	Remove air filter housing	Engine 111.951.	AR09.10-P-1150PR
4	Remove charge air duct (4)	Only for engine 111.955.	AR09.50-P-8680PK
5	Remove electric fan (5)		AR20.40-P-5000PK
6.1	Loosen poly-V-belt of basic drive (6) and secure to engine	Engine 111.955.
		Swivel stud bolt (7) at tensioning pulley (8) in anti-clockwise direction for this step (arrow) Installation: Lock tensioning pulley with pin or drift (9).
		Inspect poly V-belt (6), replace if necessary ↓
		Remove poly-V-belt	AR13.22-P-1202PK
6.2	Remove poly-V-belt	Engine 111.951.	AR13.22-P-1202PR
7	Detach vacuum line (10)
8	Detach vacuum line (11) from electrical vacuum pump (12)	To do so, press together both clamps of lock and pull out vacuum line.
9	Detach vacuum line (11) at intake manifold	To do so, press together both clamps of lock and pull out vacuum line.
10	Detach vacuum line (13) of purge valve
11	Remove intake fitting and pressure fitting (14) of compressor	Only for engine 111.955.	AR09.50-P-8841PK
12	Disconnect engine wiring harness		AR01.00-P-2410PR
	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-Z0001-01A
13	Disconnect fuel line (15)	Release fuel pressure through service valve!
		Collect fuel.
		Pressure hose	AS47.00-Z-0001-01A
			*BA47.25-P-1001-01A
14	Extract oil from expansion reservoir of power steering pump	Hand pump	Fig 4
15	Detach return line (16) and pressure line (17) of power steering pump (18)	Seal connections!
		Installation: Replace O-ring (19) of pressure line.
		Set of plugs	Figure
			*BA46.30-P-1002-01D
			*BA46.30-P-1004-01D
16	Disconnect ground lead (20) from power steering pump (18)
17	Remove lower engine compartment paneling		AR61.20-P-1105P
18	Drain and collect engine oil	Installation: Replace the seal of the oil drain screw.
			*BA01.45-P-1003-01A
			*BF18.00-P-1001-01L
	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
19	Drain coolant		AR20.00-P-1142PR
	Notes on coolant	Engine all	AH20.00-N-2080-01A
20	Detach the front exhaust system (21) on the exhaust manifold.	Installation: Install new bolts (22). Inspect rivet nuts in exhaust manifold, replace if necessary ↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
			*BA49.10-P-1005-01F
21	Remove bracket (23) of exhaust system	Installation:
		Inspect tapping plate (24), replace if necessary
			*BA49.10-P-1003-01F
			*BA49.10-P-1004-01F
22	Take off propeller shaft (25) at transmission		*BA41.10-P-1001-01A
23	Detach selector lever rod (26) from transmission	Installation: Check fuse (27), replace if necessary.
24	Detach connection hoses (28) at automatic transmission oil lines and connect using connection piece (29)	Seal connections!
		Set of plugs	Figure
	Connection fitting for automatic oil pipes		WF58.50-P-2020-01A
25	Unscrew engine mount bolts (30) at front axle carrier		*BA22.10-P-1008-01A
26	Detach coolant lines (31, 32) at thermostat housing (33)	Installation: Inspect hose clamps and coolant lines, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
27	Detach coolant lines (34, 35) at coolant pump	Installation: Inspect hose clamps and coolant lines, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
28	Detach coolant line (36) for heater	Push back clamp (37) until it locks in place; pull out coolant line.
		Installation: Check coolant line, replace if necessary.
		Replace seal of coolant line.
29	Disconnect connector (38) for refrigerant compressor (39)
30	Dismount coolant compressor (39)	Secure coolant compressor in bottom of engine compartment with lines connected.
			*BA83.55-P-1001-01F
31	Remove engine crossmember (40) with mount	Support transmission with car jack for this step.
			*BA22.10-P-1003-01A
			*BA22.10-P-1006-01A
32	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
33	Attach engine hoist to engine lifting eyes		*WE58.40-Z-1012-11A
34	Attach engine hoist to lifting eyes of engine	Lower the support (car jack) below the transmission for this step.
35	Install in the reverse order
36	Inspect cooling system for leaks	If fitting new cylinder head gasket, bring engine to operating temperature beforehand.	AR20.00-P-1010P
	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 engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
37	Check oil level in automatic transmission and correct if necessary.		AR27.00-P-0101P
38	Run engine and inspect for leaks
39	Read out fault memory and erase	STAR diagnosis!

OIL PAN

Number	Designation			Engine 111.951/955/958
BA01.45-P-1003-01A	Oil drain screw to oil pan	M12	Nm	-
BA01.45-P-1003-01A	Oil drain screw to oil pan	M14	Nm	30

Engine suspension, engine mounts, engine supports

Number	Designation		Engine 111.951/955/958 in model 203
BA22.10-P-1003-01A	Bolt connecting rear engine crossmember to body	Nm	40
BA22.10-P-1006-01A	Bolt or nut, rear engine mount to transmission	Nm	50
BA22.10-P-1008-01A	Bolt connecting front engine mounts to front axle carrier	Nm	35

DRIVESHAFT

Number	Designation			Model 203
BA41.10-P-1001-01A	Self-locking nut of flexible joint to transmission or front propeller shaft	M10	Nm	40
BA41.10-P-1001-01A		M12	Nm	60

POWER STEERING PUMP

Number	Designation		Model 203.035/043/045/235/245235/245/735/745/747
BA46.30-P-1002-01D	Connecting pipe of high-pressure expansion hose/line to power steering pump	Nm	45
BA46.30-P-1004-01D	Return line to power steering pump	Nm	2

FUEL PIPES/HOSES

Number	Designation		Engine 111.951/955
BA47.25-P-1001-01A	Separation point of feed line engine compartment	Nm	25

EXHAUST SYSTEM

Number	Designation		Engine 111 in model 203
BA49.10-P-1003-01F	Bolt connecting exhaust bracket to transmission	Nm	20
BA49.10-P-1004-01F	Self-locking nut to front exhaust pipe	Nm	20
BA49.10-P-1005-01F	Bolt connecting flange connection to exhaust pipes or exhaust manifold	Nm	20

REFRIGERANT COMPRESSOR

Number	Designation		Engine 111.951	Engine 111.955
BA83.55-P-1001-01F	Bolt connecting refrigerant compressor to bracket	Nm	20	20
BA83.55-P-1002-01F	Bolt connecting refrigerant lines to refrigerant compressor	Nm	20	20

CAPACITIES OF ENGINE LUBRICATION SYSTEM

Number	Designation			Engine 111.951/951/955
BF18.00-P-1001-01L	Engine oil	Capacity without filter	Liters	6.5
		Capacity with filter	Liters	7.0
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A

Fig 4: Identifying Hand Pump (112 589 00 72 00)

Fig 5: Identifying Pressure Hose (119 589 04 63 00)

Fig 6: Identifying Set Of Stop Plugs (129 589 00 91 00)

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