Remove/install coolant pump - AR20.10-P-1271B

ENGINE 112.945 in MODELS 463.209 /232 /233 /244 /245 /250

ENGINE 112 in MODELS 129, 163, 170, 202, 203, 208, 209, 210, 220

ENGINE 113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254

ENGINE 113 in MODELS 129, 163, 202, 203, 208, 209, 210, 220

ENGINE 113.982 in MODELS 463.243 /246

ENGINE 113.989 in MODEL 171.473

Shown on engine 112

Fig 1: Identifying Coolant Pump Components - Shown On Engine 112

MODIFICATION NOTES

16.12.03

Value changed from 10 Nm to 9 Nm

Value in BA20.10-P-1002-01M modified on engine 112.910/911/912/913/914/915/916/ 917/920/921 /922/923/940/941 /942/ 943/944/945/946/947/949/953/954/ 955/960/961 /970/972/973/975

*BA20.10-P-1002-01M

	Remove/install
	Risk of death caused by vehicle slipping or toppling off 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
1	Lift/jack up vehicle	Models 129, 170, 202, 208, 210, 220
		Model 163	AR00.60-P-1000GH
		Model 171	AR00.60-P-1000V
		Models 203, 209	AR00.60-P-1000P
		Model 463	AR00.60-P-1000G
	Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/ rear-end door or sliding roof.	When moving components, ensure that no body parts or limbs are within the operating range of moving parts.	AS00.00-Z-0011-01A
2	Open engine hood	Model 129
		Model 163.154/172 up to VINA145272	AR88.40-P-1000GH
		Model 163.154/172 up to VINX708318154/172
		Model 163.154/172 from VINA145273	AR88.40-P-1000GI
		Model 163.154/172 from VINX708319
		Models 163.157/174/175
		Model 170	AR88.40-P-1000G
		Model 171.4	AR88.40-P-1000V
		Model 202	AR88.40-P-1000E
		Model 203	AR88.40-P-1000P
		Models 208/210	AR88.40-P-1000F
		Model 209	AR88.40-P-1000Q
		Model 220	AR88.40-P-1000M
		Model 463	AR88.40-P-1000GG
3.1	Unclip cover on front side of engine	Only model 220.
4.1	Remove engine cover or air filter	All except models 170.466, 171.473, 203.065 /265, 203.076 /276, 209.376 /476 from 24.4.04.
5.1	Partially remove air filter housing	Engine 112.960 in model 170.466	AR09.10-P-1150SVK
		Engine 112.961 in models 203.065/ 265
		Engine 113.987 in models 209.376 /476 as of 24.4.04	AR09.10-P-1150AC
		ENGINE 113.988 in Models 203.076/276
		Engine 113.989 in model 171.473
6.1	Remove viscous fan (1)	All except models 163.174/175, 170, 171.473, 203, 208.365 /465, 209, 220 Right-hand thread!	AR20.40-P-5660C
7.1	Remove fan shroud (3)	On vehicles fitted with suction fan, separate the plug connection of the suction fan before removing the fan shroud.
		Model 171.473 with engine 113.989	AR20.40-P-6800VT
		Model 463 with engines 112.945, 113.962/982	AR20.40-P-6800V
		Model 220 with engines 112, 113	AR20.40-P-6800AB
8.1	Remove electric fan	Model 163 with engines 113.965/981	AR20.40-P-5000GH
		Model 170 with engines 112.947/ 960	AR20.40-P-5000SV
		Model 171.473 with engine 113.989	AR20.40-P-5000V
		Model 203.076/ 276	AR20.40-P-5000AC
		Model 203 with engines 112.912/916/ 946/953/961	AR20.40-P-5000PV
		Model 209 with engines 112.912 /955, 113.968 /987.
		Models 208.365/ 465
	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
9	Drain coolant from radiator	Model 163: For draining coolant, detach bottom coolant line at radiator or at coolant pump.
		Installation: On model 163 replace radiator connection of hose clamps to coolant hose, otherwise this can cause a damage to the bolt/ thread.
		Hose clamp	*BA20.20-P-1004-01A
		Collect coolant
		Disposal of coolants: observe legal regulations or local wastewater requirements! Refer to Environmental Protection Catalog issued by MBVD/PWU for locations in Germany.
		Models 129, 163, 202, 208, 210, 220 with engine 112	AR20.00-P-1142HA
		Models 220, 210, 208, 202, 163, 129 with engine 113
		Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962.
		Model 463.209 /232 /233 /244 /245 /250 with engine 112.945.
		Models 463.243 /246 with Engine 113.982
		Model 170.465 with engine 112.947	AR20.00-P-1142SV
		Model 170.466 with engine 112.960	AR20.00-P-1142SV
		Model 171.473 with engine 113.989	AR20.00-P-1142PV
		Models 203.061 /261 with Engine 112.912
		Models 203.064 /264 /764 with Engine 112.946
		Models 203.065 /265 with Engine 112.961
		Models 203.076 /276 with Engine 113.988
		Models 203.081 /281 with Engine 112.916
		Models 203.084 /284 with Engine 112.953
		Models 209.361 /461 with Engine 112.912
		Models 209.365 /465 with Engine 112.955
		Models 209.375 /475 with Engine 113.968
		Models 209.376 /476 with Engine 113.987
10	Remove poly-V-belt (2)	Lock tensioning pulley with drift or pin (diameter 5 mm).
		Model 463.209 /232 /233 /244 /245 /250 with engine 112.945.	AR13.22-P-1202B
		Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962.
		Models 463.243 /246 with Engine 113.982
		Models 129, 163 with engine 112
		Models 129, 202, 208.370 /470, 210 with engine 113
		Model 163 with engine 113 except 113.965/981
		Models 202, 208, 210, 220 with engine 112	AR13.22-P-1202BA
		Model 220 with engine 113 except 220.074/174
		Model 163.174 with engine 113.981
		Model 163.175 with engine 113.965
		MODELS 208.374 /474 with Engine 113
		Models 220.074/174	AR13.22-P-1202R
		Model 170.465 with engine 112.947	AR13.22-P-1202SV
		Model 170.466 with engine 112.960	AR13.22-P-1202SVK
		MODELS 203.065 /265 with ENGINE 112.961
		Model 171.473 with engine 113.989	AR13.22-P-1202PV
		Models 203.061 /261 with Engine 112.912
		Models 203.064 /264 /764 with Engine 112.946
		Models 203.076 /276 with Engine 113.988
		Models 203.081 /281 with Engine 112.916
		Models 203.084 /284 with Engine 112.953
		Models 209.361 /461 with Engine 112.912
		Models 209.365 /465 with Engine 112.955
		Models 209.375 /475 with Engine 113.968
		Models 209.376 /476 with Engine 113.987
11.1	Remove shock absorber (10)	Models 210, 203, 209, 202, 170, 129 with manual transmission
12	Remove poly-V-belt tensioning device	Model 463.209 /232 /233 /244 /245 /250 with engine 112.945.	AR13.25-P-3200B
		Model 463.206 /240 /241 /247 /248 / 249 /254 with engine 113.962.
		Models 463.243 /246 with Engine 113.982
		Models 129, 163 with engine 112
		Models 129, 202, 208, 210 with engine 113
		Model 163 with engine 113 except 113.965/981
		Model 163.174 with engine113.981	AR13.25-P-3200BA
		Model 163.175 with engine 113.965
		Models 170, 202, 203, 208, 209, 210, 220 with engine 112
		Model 171.473 with engine 113.989
		Models 203, 209, 220 with engine 113
13	Disconnect coolant hose (4, 5)	Check condition of coolant hoses and hose clamps, replace if necessary.
14.1	Disconnect coolant hose (6) at oil-water heat exchanger	All except model 171.473. Check condition of coolant hose and hose clamp, replace if necessary.
15.1	Remove bolts from oil lines on oil filter	Only model 171.473.
		Bolt of oil line to oil filter housing	*BA18.20-P-1003-01D
16.1	Remove bolts from oil lines brackets and lay oil lines with brackets to one side	Only model 171.473. Bolt, oil line bracket	*BA18.20-P-1004-01D
17.1	Remove bracket with switchover valve and pressure sensor and place to one side	Only model 171.473
18	Take off belt pulley of coolant pump (7)	Engine 112: ↓
		Belt pulley to coolant pump	*BA20.10-P-1002-01M
		Engine 113, except 113.987 /988 / 989 /991: ↓
		Belt pulley to coolant pump	*BA20.10-P-1002-01C
		Engines 113.987 /988/989 /991: ↓
		Belt pulley to coolant pump	*BA20.10-P-1002-01L
		Engine 113.989: ↓
		Counterholder	Fig 3
19	Remove coolant pump (8)	Installation: Replace gasket of coolant pump (9).
		Engine 112: ↓
		Self-tapping screw, coolant pump to timing case	*BA20.10-P-1001-01M
		Engine 113 except 113.987 /988 / 989 /991: ↓	*BA20.10-P-1001-01M
		Self-tapping screw, coolant pump to timing case	*BA20.10-P-1001-01C
		Engines 113.987 /988/989 /991: ↓
		Bolt, coolant pump to timing case	*BA20.10-P-1001-01L
		Engine 112, 113: ↓
		Alternator screw	*BA15.40-P-1003-01A
		External Torx set	Fig 2
20	Install in the reverse order
21	Inspect cooling system for leaks	All except models 170, 171.473, 203, 209, 220.074/174	AR20.00-P-1010HA
		Models 170, 171.473, 203, 209	AR20.00-P-1010P
		Models 220.074/174	AR20.00-P-1010RVK

ALTERNATOR

Number	Designation		Engines 112.91/92/94/ 953/954/955/ 96/97, 113.94/96/98	Engine 113.991 in models 215, 220
BA15.40-P-1003-01A	Bolt for alternator	Nm	42	-

OIL FILTER

Number	Designation		Engine 113.989
BA18.20-P-1003-01D	Bolt, oil line to oil filter housing	Nm	9
BA18.20-P-1004-01D	Bolt for oil line bracket	Nm	-

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation				Engines 112.910/911/91 2/913/914/915/ 916/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 953/954/955/ 960/961/970/ 972/973/975
BA20.10-P-1001-01M	Self-tapping screw, coolant pump to timing case	Thread not pre-tapped	M6	Nm	14
		Thread not pre-tapped	M8	Nm	35
		Thread pre-tapped	M6	Nm	10
		Thread pre-tapped	M8	Nm	25
BA20.10-P-1002-01M	Belt pulley to coolant pump			Nm	9

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation				Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/965/966/ 967/968/969/ 980/981/982/ 984/986/992 993/995
BA20.10-P-1001-01C	Self-tapping screw, coolant pump to timing case	Thread not pre-tapped	M6	Nm	14
		Thread not pre-tapped	M8	Nm	35
		Thread pre-tapped	M6	Nm	10
		Thread pre-tapped	M8	Nm	25
BA20.10-P-1002-01C	Belt pulley to coolant pump			Nm	10

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation			Engine 113.987/988/ 990/991	Engine 113.989
BA20.10-P-1001-01L	Bolt, coolant pump to timing case	M6	Nm	14	14
BA20.10-P-1001-01L	Bolt, coolant pump to timing case	M8	Nm	20	20
BA20.10-P-1002-01L	Belt pulley to coolant pump		Nm	9	9

RADIATOR, COOLANT HOSES

Number	Designation		Engines 112.942/ 970, 113.942/ 965/981
BA20.20-P-1004-01A	Hose clamp	Nm	3

Fig 2: Identifying External Torx Set (001 589 76 09 00)

Fig 3: Identifying Counterholder (113 589 00 40 00)