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

ENGINE 111.951 in MODEL 203.035 /235 /735 with TRANSMISSION 716.6

ENGINE 111.955 in MODEL 203.045 /245 /745 with TRANSMISSION 716.6

Shown on engine 111.951

Fig 1: Identifying Engine Remove/Install Components - Shown On Engine 111.951 With Transmission 716.6 (1 Of 3)

Fig 2: Identifying Engine Remove/Install Components - Shown On Engine 111.951 With Transmission 716.6 (2 Of 3)

Fig 3: Identifying Engine Remove/Install Components - Shown On Engine 111.951 With Transmission 716.6 (3 Of 3)

MODIFICATION NOTES

22.9.03

Reference address subdivided as per production period

Step 44

	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		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).	Engine 111.951	AR09.10-P-1150PR
3.2	Remove air filter housing with air recirculation flap actuator	Engine 111.955
		Remove air filter housing	AR09.10-P-1150PK
		Remove air recirculation flap actuator with resonance body	AR09.50-P-8842PK
4.1	Remove left charge air duct	Engine 111.955	AR09.50-P-8680PK
5	Remove electric fan (3)		AR20.40-P-5000PR
6.1	Remove poly-V belt (4)	Engine 111.951	AR13.22-P-1202PR
6.2	Loosen poly-V-belt (4) of basic drive and secure to engine	Engine 111.955
		Installation: Check poly-V-belts and replace if necessary. ↓
		Remove poly-V-belt	AR13.22-P-1202PK
7	Disconnect vacuum line of brake booster at connection (5) of intake manifold	To do this, press the two clamps (arrows) together and pull out the vacuum line.
8	Detach vacuum line (6) of purge valve	Remove tie straps
	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
9	Disconnect fuel line (7)	Release fuel pressure through service valve!
		Collect fuel.
		Pressure hose	Figure
			*BA47.25-P-1001-01A
10.1	Remove intake fitting and pressure fitting of compressor	Engine 111.955	AR09.50-P-8841PK
11	Disconnect engine wiring harness		AR01.00-P-2410PR
12	Disconnect power steering pump ground lead (8)
13	Extract oil from expansion reservoir of power steering pump (11).	Hand pump	Figure
14	Detach return flow line (10) and pressure line (9) at the power steering pump (11)	Seal connections!
		Installation: Replace O-ring (12) of pressure line.
		Set of plugs	Figure
			*BA46.30-P-1002-01D
			*BA46.30-P-1004-01D
15	Remove lower engine compartment paneling		AR61.20-P-1105P
16	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
17	Drain coolant		AR20.00-P-1142PR
	Notes on coolant		AH20.00-N-2080-01A
18	Detach the front exhaust system (13) on the exhaust manifold.	Installation: Replace screws. 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
19	Remove bracket (14) of exhaust system	Installation: Check tapping plate, replace if necessary.
			*BA49.10-P-1003-01F
			*BA49.10-P-1004-01F
20	Take off propeller shaft (15) at transmission		*BA41.10-P-1001-01A
21	Remove engine crossmember (16) with engine mount	For this step, support the transmission.
22	Detach selector cable (17) at transmission	Remove cover (18) first of all.
23	Lower transmission slightly	Lower transmission only far enough until the center shift (19) and the shift rod (20) are accessible.
24	Remove locking pin (21) and detach center shift (19)	Installation: Check safety bolt (21), replace if necessary.
25	Unhook shift rod (20)	Installation: Slightly grease ball socket (22) of gearshift linkage.	*BR00.45-Z-1001-06A
26	Install engine crossmember (16) with engine mount		*BA22.10-P-1003-01A
			*BA22.10-P-1006-01A
	Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.	Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.	AS42.50-Z-0001-01A
27	Separate line (23) of hydraulic clutch	Collect brake fluid.
		Seal connections.
		Set of plugs	Figure
		Installation: Bleed clutch system.	AR25.20-P-0070P
	Brake fluid notes		AH42.50-P-0001-01A
28	Unscrew bolts (24) of engine mounts (25) at front axle carrier on right and left		*BA22.10-P-1008-01A
29.1	Remove air pump	Engine 111.951	AR14.30-P-7251PR
30	Detach coolant line (26) at thermostat housing (27)	Installation: Check hose clamp and coolant line, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
31	Detach coolant line (28) at thermostat housing (27)	Installation: Check hose clamp and coolant line, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
32	Detach coolant line (29) at coolant pump (30)	Installation: Check hose clamp and coolant line, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
33	Detach coolant line (31) at coolant pump (30)	Installation: Check hose clamp and coolant line, replace if necessary.
			*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
34	Detach coolant line (32) for heater	Push back clamp (33) until it locks in place and pull out coolant line.
		Installation: Check coolant line, replace if necessary.
		Replace seal of coolant line.
35	Disconnect connector (34) for coolant compressor (35)
36	Dismount coolant compressor (35)	Secure coolant compressor in bottom of engine compartment with lines connected.
			*BA83.55-P-1001-01F
37	Remove engine crossmember (16) with engine mount	Support transmission with car jack for this step.
			*BA22.10-P-1003-01A
			*BA22.10-P-1006-01A
38	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
39	Attach engine hoist to engine lifting eyes		*WE58.40-Z-1012-11A
40	Attach engine hoist to lifting eyes of engine	Lower the support (car jack) below the transmission for this step.
41	Install in the reverse order
42	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
43	Run engine and inspect for leaks
44	Check gearshift for ease of movement	If gearshift is sluggish: ↓
		Adjust selector cable
		Vehicles up to approx. 06/2000
		Model 203.035/ 045	AR26.60-P-0635-02D
		Vehicles as of 06/2000
		Model 203.035/ 045/ 235/ 245/ 735/ 745	AR26.60-P-0635-02E
45	Read out fault memory and erase	STAR DIAGNOSIS diagnosis system	*WH58.30-Z-1048-13A

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 connecting 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 connecting 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	Connection fitting 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

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

WORKSHOP EQUIPMENT

WE58.40-Z-1012-11A

Load regulator (engine hoist), self-locking

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51