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

ENGINE 112, 113 / (except 112.975, 113.948 /966) in MODEL 220

Fig 1: Identifying Engine Remove/Install Components (1 Of 3)

Fig 2: Identifying Engine Remove/Install Components (2 Of 3)

Fig 3: Identifying Engine Remove/Install Components (3 Of 3)

	Remove/install
	Risk of death caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of vehicle lift and position four support plates at vehicle lift 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
	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 lead-acid 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 line		AR54.10-P-0003I
	Notes on battery		AH54.10-P-0001-01A
2	Remove lower engine compartment paneling		AR61.20-P-1105M
	Risk of injury to skin and eyes due to scalding caused by contact with hot coolant spray	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure.	AS20.00-Z-0001-01A
	Risk of poisoning caused by swallowing coolant.	Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.
3	Drain coolant at radiator		AR20.00-P-1142HA
	Notes on coolant		AH20.00-N-2080-01A
4	Drain and collect engine oil	Installation: Replace sealing ring of oil drain screw.
		Oil drain screw to oil pan	*BA01.45-P-1003-01B
		Engine oil filling capacity	*BF18.00-P-1001-01H
5	Unclip cover at face end of engine
6	Remove air filter housing (6)	Take off intake pipes for this step.
7	Inspect both rear engine lifting eyes for marking	Engine suspension lugs without identification must be replaced.
			BT01.00-P-0001-01A
8	Remove fan shroud with fan (1)		AR20.40-P-6800AB
9	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
10	Detach coolant lines (16, 17) from coolant pump
11	Detach coolant line (19) from thermostat housing
12	Detach coolant line at top of expansion reservoir
13	Detach vacuum line (4) from brake booster at rear of intake manifold
14	Extract power steering pump (7) oil	Hand pump	Fig 4
15	Detach suction and pressure oil lines from power steering pump (7)	Seal the connections.
			*BA46.30-P-1002-01C
			*BA46.30-P-1003-01C
16	Detach vacuum hose (5) at purge control valve
	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
17	Disconnect fuel line (3)	Open tank lock before disconnecting.
18	Detach heater hose (18) from firewall
19	Disconnect engine wiring harness		AR01.00-P-2410M
20	Remove poly-V belt (2)	Installation: Lock clamping device with 5 mm ø drift or pin.	AR13.22-P-1202BA
21	Disconnect automatic transmission oil lines (14, 15)	Plug openings.
			*BA20.20-P-1001-01A
22	Disconnect connector from refrigerant compressor (A9)
23	Unscrew bolts for refrigerant compressor (A9)	Attach refrigerant compressor (A9) to bottom of engine compartment with lines connected.	AR83.55-P-5300M
			*BA83.55-P-1001-01A
24	Remove front exhaust system (9)	Support rear exhaust system. Installation: In vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.	AR49.10-P-7000AA
25	Detach exhaust bracket (10) from transmission
26	Detach shift rod from transmission
27	Remove rear engine crossmember (12)		AR22.10-P-1160AB
			*BA22.10-P-1002-01L
			*BA22.10-P-1003-01L
28	Disconnect front propeller shaft section (11) from transmission	The flexible coupling remains on the propeller shaft.
		Installation: Connect front propeller shaft to transmission	AR41.10-P-0050-07I
			*BA41.10-P-1001-01A
29	Loosen fitted sleeves of flexible coupling and push back propeller shaft		AR41.10-P-0050-09I
	Drift for loosening fitting sleeves in flex disks.		WF58.50-P-4110-01A
30	Unscrew bolts of front engine mount (13) at front axle carrier		AR22.10-P-1260A
			*BA22.10-P-1001-01L
31	Attach engine hoist to engine lifting eyes
32	Lower engine towards the rear and lift out	Ensure that rear of engine does not touch firewall.
33	Install in the reverse order
	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 engine as it is running	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
34	Fill power steering pump and bleed	Vehicles without ABC code 487	AR46.30-P-0010B
		Vehicles with ABC code 487	AR46.30-P-0010N
35	Bleed cooling system	Warm up engine to operating temperature and set temperature control of heater to warm.
36	Inspecting 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-1010HA
37	Check engine oil level
38	Check oil level in automatic transmission, correct if necessary		AR27.00-P-0100AC
39	Check for leaks with engine running
40	Perform basic programming		AR00.19-P-0200M
41	Read out fault memory with STAR DIAGNOSIS and erase if necessary.	STAR DIAGNOSIS diagnosis system Stored faults which can result from removal and installation or test work, have to be processed and erased in the fault memories after completing the work.

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	Engines 112.916/953/975, 113.948/966
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30	30

OIL PAN

Number	Designation			Engine 113.940/941/942/943/944/945/946/960/961/962/963/965/967/968/969/980/981/982/984/986/992/995	Engine 113.987/988/991
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30	30

RADIATOR, COOLANT HOSES

Number	Designation		Engine 112 except 112.942/970, engines 113.940/941/943/944/945/946/948/960/961/962/963/966/967/968/969/980/982/984/986/992/993/995	Engine 113.987/988/990/991
BA20.20-P-1001-01A	Union nut, automatic transmission oil line to radiator	NM	20	18

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		Engine 112.922/944/972, 113.941/960, 137.970 in model 220
BA22.10-P-1001-01L	Bolt, front engine mount to front axle carrier	Nm	35
BA22.10-P-1002-01L	Bolt, rear engine mount to rear engine crossmember	Nm	30
BA22.10-P-1003-01L	Bolt, rear engine crossmember to body	Nm	40

PROPELLER SHAFT

Number	Designation			Model 215	Model 220
BA41.10-P-1001-01A	Self-locking nut, flexible coupling to transmission or front propeller shaft	M10	Nm	-	-
BA41.10-P-1001-01A		M12	Nm	60	60

POWER STEERING PUMP

Number	Designation			Model 220.063/065/070/073/075/165/170/173/175 without code 487a
BA46.30-P-1002-01C	Return line to power steering pump		Nm	2
BA46.30-P-1003-01C	High-pressure expansion hose to power steering pump	M14x1.5	Nm	-
BA46.30-P-1003-01C	High-pressure expansion hose to power steering pump	M16x1.5	Nm	40

REFRIGERANT COMPRESSOR

Number	Designation		Engine 112.922/944 in model 220	Engine 113.941/960 in model 220
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20	20

ENGINE LUBRICATION

Number	Designation			Engine 112 except 112.916/953/975	Engines 113.940/941/942/943/960/961/962/969/982	Engine 113.944/980/98 1/984/986/991
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	8.0	8.0	7.5
		Filling capacity without oil filter	Liters	7.5	-	-
		Specifications for Operating Fluids	Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A	BB00.40-P-0229-05A

COOLING SYSTEM

Number	Designation			Engine 112.922/944/972 in model 220	Engine 113.941/960 in model 220
BF20.00-P-1001-02K	Cooling system	Total filling capacity	Liters	≈ 10.5	≈ 11.5
		Capacity of anticorrosion/antifreeze agent down to -37°C	Liters	≈ 5.0	≈ 5.75
		Filling capacity of anticorrosion/antifreeze down to -45°C	Liters	≈ 5.5	≈ 6.25
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0325-00A	BB00.40-P-0325-02A

Fig 4: Identifying Hand Pump (210 589 00 71 00)