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

ENGINE 112.912 in MODEL 203.061 /261, 209.361 /461 with TRANSMISSION 716.6, 722.6

ENGINE 112.955 in MODEL 209.365 /465 with TRANSMISSION 722.6

ENGINE 112.961 in MODEL 203.065 /265 with TRANSMISSION 722.6

ENGINE 112.946 in MODEL 203.064 /264 with TRANSMISSION 722.6

Fig 1: Identifying Engine Remove/Install Components - Engine 112.912/946/961 (1 Of 4)

Fig 2: Identifying Engine Remove/Install Components - Engine 112.912/946/961 (2 Of 4)

Fig 3: Identifying Engine Remove/Install Components - Engine 112.912/946/961 (3 Of 4)

Fig 4: Identifying Engine Remove/Install Components - Engine 112.912/946/961, Shown On Engine 112 With Transmission 716.6 (4 Of 4)

Shown on engine 112 with transmission 716.6

	Remove/install
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	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
	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
	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
	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 from moving 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
	Notes on coolant	All engines	AH20.00-N-2080-01A
	Brake fluid notes	All models	AH42.50-P-0001-01A
	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
1	Disconnect battery ground cable
	Notes on battery	All models	AH54.10-P-0001-01A
		Model 203	AR54.10-P-0003P
		Model 209	AR54.10-P-0003Q
2.1	Remove engine cover with integrated air filter and both air inlet pipes (2)	Except model 203.065/265
		Pull engine cover with integrated air filter vertically upwards off the cylinder head covers. Installation: Moisten slightly with antifriction agent the rubber retainers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor (B2/5) in the air filter housing.
		Lubricant	*BR00.45-Z-1002-06A
2.2	Remove air filter housing (1) with air inlet pipes (2)	Model 203.065/265	AR09.10-P-1150SVK
3	Remove electric fan (3)		AR20.40-P-5000PV
4	Remove poly-V belt (4)	Engine 112.912 in model 203.061/261, 209.361/461 Engine 112.946 in model 203.064/264 Engine 112.955 in model 209.365/465	AR13.22-P-1202PV
		Model 203.065/265	AR13.22-P-1202SVK
5.1	Remove hot film mass air flow sensor (B2/5)	Engine 112.912 in model 203.061/261/, 209.361/461 Engine 112.946 in model 203.064/ 264 Engine 112.955 in model 209.365/465	AR07.07-P-1454SV
6	Disconnect vacuum line (5) at rear of intake manifold
7	Detach vacuum line (6)
8	Detach vacuum line (6) on intake manifold	To do so, press together both clamps (arrows) and pull out vacuum line (6).
9	Disconnect engine wiring harness		AR01.00-P-2410PV
10	Disconnect fuel line (8) at fuel distributor	Reduce fuel pressure via service valve. Collect fuel.
		Disconnect fuel feed line at fuel distributor	*BA07.52-P-1001-01A
		Pressure hose	Figure
11	Extract oil from power steering expansion reservoir (9)	Hand pump	Figure
12	Remove return line for power steering (11)	Detach on power steering expansion reservoir (9). Seal the connections. Installation: Check condition of hose clamp and power steering return line (11), replace if necessary.
		Return flow line at power steering pump	*BA46.30-P-1004-01D
		Set of stop plugs	Figure
13	Detach pressure line power steering (12) at power steering pump (10).	Seal the connections.
		Banjo bolt connecting high pressure expansion hose to power steering pump	*BA46.30-P-1003-01D
		Set of stop plugs	Figure
14	Detach power steering pump ground line (13)
15	Remove engine compartment paneling		AR61.20-P-1105P
16	Drain coolant from radiator		AR20.00-P-1142PV
17	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
18	Disconnect front exhaust system (14) at right and left exhaust manifold	Installation: On vehicles with engine damage the front exhaust system must be examined for swarf and any swarf present removed before installing. Installation: Replace bolts. Inspect rivet nuts in exhaust manifold, replace if necessary. ↓
		Replace rivet nuts in exhaust manifold.	AR49.10-P-5531-01DA
		Flange connection for exhaust manifold and front exhaust pipes	*BA14.10-P-1002-01B
19	Remove exhaust bracket (15)	Installation: Replace tapping plates (16) and nuts.
		Bolt connecting exhaust bracket to transmission	*BA49.10-P-1007-01A
		Self-locking nut on front exhaust pipe	*BA49.10-P-1008-01A
20	Take off propeller shaft (17) at transmission	Self-locking nut connecting flexible coupling to transmission or front section of driveshaft	*BA41.10-P-1001-01A
21.1	Detach selector lever rod (19) from transmission	Only with transmission 722.6. Installation: Check fuse (20), replace if necessary.
22.1	Remove engine crossmember (18) with mount	With transmission 716.6 Support transmission with car jack for this step.
23.1	Detach selector cable (37) at transmission	With transmission 716.6 Remove cover (38) first of all.
24.1	Lower transmission	With transmission 716.6 Only lower transmission far enough until the floor shift (39) and the shift rod (40) are accessible.
25.1	Remove safety bolts (41)	With transmission 716.6 Installation: Check safety bolt (41), replace if necessary.
26.1	Unhook center shifter console (39)	With transmission 716.6 Installation: Check safety bolt (41), replace if necessary.
27.1	Unhook shift rod (40)	With transmission 716.6 Installation: Lightly grease ball socket (42) of gearshift linkage.
		Long-life grease	*BR00.45-Z-1001-06A
28.1	Install engine cross member (18) together with mount	With transmission 716.6 Engine 112.912 in model 209
		Bolt connecting rear engine crossmember to body Engine 112.912 in model 203	*BA22.10-P-1003-01L
		Bolt connecting rear engine crossmember to body Engine 112.912 in model 209	*BA22.10-P-1003-01R
		Bolt or nut connecting rear engine mount to transmission Engine 112.912 in model 203	*BA22.10-P-1006-01L
		Bolt or nut connecting rear engine mount to transmission	*BA22.10-P-1006-01R
29.1	Disconnect line of hydraulic clutch (43)	With transmission 716.6 Collect brake fluid. Seal connections.
		Set of stop plugs	Figure
30.1	Disconnect connector hoses of automatic oil lines (21) at the oil lines (22) and connect with connection fitting of automatic oil lines (23)	With transmission 722.6
	Connection fitting for automatic oil pipes		WF58.50-P-2020-01A
		Seal the connections.
		Set of stop plugs	Figure
31	Unscrew bolts (24) of engine mounts (25) at front axle carrier	Engine 112.912 in model 209, engine 112.955 in model 209
		Bolt connecting front engine mount to front subframe.	*BA22.10-P-1001-01L
		Engine 112.912/946/961 in model 203
		Bolt connecting front engine mount to front subframe	*BA22.10-P-1001-01R
32	Detach refrigerant compressor (A9)	Attach refrigerant compressor (A9) to bottom of engine compartment with lines connected.
		Refrigerant compressor bolt to bracket	*BA83.55-P-1001-01F
33	Disconnect refrigerant compressor connector (35)
34	Detach coolant hose (26) on thermostat housing (27)	Installation: Check condition of hose clamp and coolant line (26), replace if necessary.
		6 mm socket hexagon	*WH58.30-Z-1001-06A
		7 mm socket hexagon	*WH58.30-Z-1002-06A
35	Remove coolant hose (28) on expansion reservoir (29)	Installation: Check condition of hose clamp and coolant line (28), replace if necessary.
		6 mm socket hexagon	*WH58.30-Z-1001-06A
		7 mm socket hexagon	*WH58.30-Z-1002-06A
36	Detach coolant hoses (30, 31) at coolant pump (32)	Installation: Check condition of hose clamps and coolant hoses (30, 31), replace if necessary.
		6 mm socket hexagon	*WH58.30-Z-1001-06A
		7 mm socket hexagon	*WH58.30-Z-1002-06A
37	Detach coolant hose (33) from radiator tank	Push back clamp (34) until it locks in place; pull out coolant hose (33). Installation: Check coolant hose (33), replace if necessary. Replace sealing ring on coolant hose (33).
38	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
39	Support transmission with car jack.
40.1	Remove engine crossmember (18) with mount	With transmission 716.6
41	Attach engine hoist to engine lifting eyes	Engine hoist (self-locking)	*WE58.40-Z-1012-11A
42	Attach engine hoist to lifting eyes of engine	Lower the support (car jack) below transmission for this step.
43	Install in the reverse order
44.1	Bleed clutch system	With transmission 716.6	AR25.20-P-0070P
45	Bleed cooling system	Warm up the engine to normal operating temperature and set the temperature control of heating to warm.
46	Inspect cooling system for leaks	If cylinder head gaskets are new, first warm up engine to operating temperature otherwise complete filling of the engine with coolant is not assured.	AR20.00-P-1010P
47	Check engine oil level	Engine 112.912/946 in model 203 Engine 912/955112 in model 209	AR18.00-P-3035-01A
		Engine 112.961 in model 203 AMG	AR18.00-P-3035-01BA
48.1	Check oil level in automatic transmission, correct if necessary	With transmission 722.6	AR27.00-P-0101P
49	Check for leaks with engine running
50	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
51	Carry out function check

OIL PAN

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
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30

FUEL DISTRIBUTOR

Number	Designation		Engine 112 except 112.945/951/960/961	Engine 112.960/961 AMG
BA07.52-P-1001-01A	Fuel feed line to fuel distributor	Nm	38	35

EXHAUST MANIFOLD

Number	Designation		Engine 112 except 112.951/976
BA14.10-P-1002-01B	Flange connection for exhaust manifold and front exhaust pipes	Nm	20

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation			Engine 112.912 in model 209	Engine 112.955 in model 209
BA22.10-P-1001-01L	Bolt connecting front engine mounts to front axle carrier		Nm	35	35
BA22.10-P-1003-01L	Bolt connecting rear engine crossmember to body		Nm	40	40
BA22.10-P-1006-01L	Bolt or nut connecting rear engine mount to transmission	M8	Nm	-	-
BA22.10-P-1006-01L	Bolt or nut connecting rear engine mount to transmission	M10	Nm	50	40

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation			Engine 112.912/946 in model 203	Engine 112.961 in model 203
BA22.10-P-1001-01R	Bolt connecting front engine mounts to front axle carrier		Nm	35	35
BA22.10-P-1003-01R	Bolt connecting rear engine crossmember to body	Left	Nm	40	-
BA22.10-P-1003-01R	Bolt connecting rear engine crossmember to body	Right	Nm	33	-
BA22.10-P-1006-01R	Bolt or nut connecting rear engine mount to transmission	M8	Nm	-	-
BA22.10-P-1006-01R	Bolt or nut connecting rear engine mount to transmission	M10	Nm	50	50

DRIVESHAFT

Number	Designation			Model 203	Model 209
BA41.10-P-1001-01A	Self-locking nut connecting flexible joint to transmission or front propeller shaft	M10	Nm	40	40
BA41.10-P-1001-01A		M12	Nm	60	60

POWER STEERING PUMP

Number	Designation		Model 203.061/064/065/076/081/084/243/261/264/265/276/764 Model 203.281/284 without level control	Model 209.316/361/365/372/375/376/377/461/465/472/475/476/477
BA46.30-P-1003-01D	Banjo bolt connecting high pressure flexible hose to power steering pump	Nm	45	45
BA46.30-P-1004-01D	Return line to power steering pump	Nm	2	2

EXHAUST SYSTEM

Number	Designation		Engines 112, 113 in model 203
BA49.10-P-1007-01A	Bolt connecting exhaust bracket to transmission	Nm	20
BA49.10-P-1008-01A	Self-locking nut to front exhaust pipe	Nm	20

REFRIGERANT COMPRESSOR

Number	Designation		Engine 112.912/946/961	Engine 112.913/917/949/954/955
BA83.55-P-1001-01F	Bolt connecting refrigerant compressor to bracket	Nm	20	20

ENGINE LUBRICATION

Number	Designation			Engine 112 except 112.916/953/975
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	8.0
		Filling capacity without oil filter	Liters	7.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A

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

Fig 6: Identifying Pressure Hose (119 589 04 63 00)

Fig 7: 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
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-1002-06A	Lubricant	A 000 989 01 60
BR00.45-Z-1001-06A	Long-life grease	A 000 989 63 51