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

ENGINE 113.992 in MODEL 230.474

ENGINE 113.990 in MODEL 211.076 /276

ENGINE 113.991 in MODEL 215.374

ENGINE 113.991 in MODEL 220.074

ENGINE 113.995 in MODEL 230.472

Fig 1: Identifying Engine Remove/Install Components (1 Of 2)

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

Fig 3: Identifying Engine Remove/Install Components (Illustrated On Model 230.474)

Illustrated on model 230.474

Fig 4: Identifying Engine Remove/Install Components

MODIFICATION NOTES

18.4.06

Banjo bolt, high pressure expansion hose to power steering pump

Model 211 with engine 112, 113

*BA46.30-P-1002-01M

	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 injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid.	Depressurize the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.	AS00.00-Z-0013-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Selector lever in position "N"
	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 glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
2	Detach ground line(s) at battery(ies)	Turn key in electronic ignition switch EIS into position "0". Key cannot be withdrawn. Vehicle with Keyless Go code 889: Switch off engine, remove Keyless Go cards from vehicle and keep outside range of transmitter.
		Model 211.076	AR54.10-P-0003T
		Model 211.276	AR54.10-P-0003TA
		Model 215, 220	AR54.10-P-0003I
		Model 230	AR54.10-P-0003R
3	Remove air filter housing (1).		AR09.10-P-1150SVK
4	Detach purge vacuum hose (2) to 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
5	Disconnect fuel line (17/2)	Release fuel pressure through service valve.
			*BA07.52-P-1001-01A
		Pressure hose	Figure
6	Disconnect engine wiring harness	Only separation points in engine compartment.	AR01.00-P-2410R
7.1	Disconnect vacuum connection to brake booster	Model 215, 220
8.1	Extract hydraulic fluid from both reservoirs of the power steering pump (30)	Model 215, 220, 230
		Hand pump	Figure
8.2	Suction off the oil from the reservoir of the power steering pump (30)	Model 211
		Hand pump	Figure
9.1	Disconnect feed line to power steering pump (30f) and feed line to power steering pump (58) at power steering pump (30)	Model 215, 220, 230
		Seal the connections.
		Set of stop plugs	Figure
9.2	Remove return line on supply reservoir (30) for power steering pump	Model 211
		Seal connection.
		Set of stop plugs	Figure
10.1	Detach high pressure flexible hose (30i) and remove power steering pump (30)	Model 215, 220, 230
		Installation: Replace O-ring, in order to preclude leakages.
10.2	Dismount high pressure hose at power steering pump (30)	Model 211
		Installation: Replace O-ring, in order to preclude leakages.
			*BA46.30-P-1002-01M
11	Disconnect electrical connector of ABC suction restrictor valve (Y86/1)
12	Remove engine compartment paneling	Model 230	AR61.20-P-1105R
		Model 211	AR61.20-P-1105T
		Model 215, 220	AR61.20-P-1105M
13	Remove automatic transmission oil lines (3, 4) at radiator	Seal the connections.
		Installation: Check oil level in automatic transmission; correct if necessary.	AR27.00-P-0100AC
			*BA20.20-P-1001-01A
		Set of stop plugs	Figure
14	Dismount bolts of oil lines to oil filter housing		*BA18.20-P-1003-01D
15	Unscrew Bolt, bracket of oil lines		*BA18.20-P-1004-01D
16	Remove oil lines and close	Installation: Replace O-rings, in order to preclude leakages.
		Set of stop plugs	Figure
17	Remove fan shroud (5)	Model 215, 220, 230	AR20.40-P-6800AB
		Model 211	AR20.40-P-6800TC
18	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
	Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.	AS83.00-Z-0001-01A
19	Discharge air conditioning system
	Procedure for a damaged or leaky air conditioning system		AH83.30-N-0004-01A
	Protect air conditioning circuit and components from moisture when carrying out repair work		AH83.30-N-0005-01A
	Notes on handling refrigerant R134a		AH83.30-N-0003-01A
		Recycle refrigerant and note quantity of extracted compressor oil. Installation: Evacuate air conditioning and fill, at the same time lead new compressor oil to the refrigerant circuit. Observe the noted compressor oil quantity. Check air conditioning system refrigerant circuit for leaks.
		Filling capacity	*BF83.00-P-1001-01A
		For refrigerant compressor 7SEU16C in Model 211, 230	*BF83.55-P-1005-01A
		For refrigerant compressor 7SE16 in model 215, 220	*BF83.55-P-1005-01A
20	Unscrew bolt for separation point of suction line (17)		*BA83.30-P-1010-01A
21	Dismount suction line at separation point	Installation: Replace O-ring and moisten with compressor oil.
		Set of plugs	Figure
	Risk of injury to skin and eyes due to scalding caused by contact with hot coolant spray Risk of poisoning caused by 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
22	Drain coolant at radiator, pour in		AR20.00-P-1142RVK
			*BF20.00-P-1001-02K
23	Drain and collect engine oil		*BA01.45-P-1003-01B
			*BF18.00-P-1001-01H
24	Disconnect electrical connectors for lambda and diagnosis sensors	Unclip electrical feed lines from retaining clamps.
25	Remove exhaust system (6) as of flange connection for exhaust manifold	Installation: On vehicles with engine damage the exhaust system (6) must be studied for the presence of swarf before assembly and swarf must be removed if existing, otherwise consequential damage could reoccur.
		Model 211	AR49.10-P-7000TB
		Model 220, 215	AR49.10-P-7000AA
		Model 230	AR49.10-P-7000RA
26	Disconnect engine wiring harness	Only separation points at underbody.	AR01.00-P-2410R
27.1	Remove bracket (7) of engine compartment paneling	Only model 211, 230
28	Remove bracket for engine compartment paneling behind transmission
29	Support transmission with transmission jack and transmission plate
30	Remove rear engine mounts (8)	Model 215, 220, 230	AR22.10-P-1160AB
		Model 211	AR22.10-P-1160T
31	Unbolt propeller shaft (9) at transmission	The flexible coupling remains on the propeller shaft (9).
32	Detach shift rod (10) from transmission
33	Install rear engine support (11)	Without rear engine mount (8).
		Engine 113 in model 211, 215, 220	*BA22.10-P-1003-01L
		Engine 113 in model 230	*BA22.10-P-1003-01X
34	Lower transmission onto rear engine support (11)	In order to avoid damages of the detachable body components, ensure that the engine is not touching the splash wall.
35	Unscrew bolt, front engine mount (12) at front axle carrier
36	Open plastic clip (13a) on coolant line at coolant pump (13)
37	Disconnect coolant line at coolant pump (13) and coolant line at coolant pump (14)
38	Unscrew nut of pressure and hot gas line to condenser (16)		*BA83.30-P-1011-01A
39	Remove high pressure expansion hose (30m) bracket at oil pan
40	Detach heater hose (15) from firewall	Set of stop plugs	Figure
41	Remove coolant hose between radiator and thermostat housing
42.1	Disconnect ABC high pressure hose (59) at power steering pump (30)	Model 215, 220, 230 Installation: Replace O-rings, in order to preclude leakages.
43.1	Remove ABS high pressure hose (59) to pressure limiting valve (18)	Model 215, 220, 230 Unbolt banjo bolt to pressure limiting valve (18).
44.1	Remove brackets on ABC high pressure hose (59) from refrigerant compressor, oil pan and transmission bell	Model 230
45	Disconnect electrical connector at refrigerant compressor
46	Mount bracket on supercharger housing	Bracket	Fig 5
47	Attach engine hoist to engine lifting eyes
48	Lift out engine
49	Install in the reverse order
50	Remove/install drier cartridge ridge of air conditioning system	The drier cartridge generally has to be replaced if the refrigerant circuit has been opened. The drier cartridge is hygroscopic (absorbs humidity).
		Model 211	AR83.30-P-6520T
		Model 215, 220	AR83.30-P-6520M
		Model 230	AR83.30-P-6520R
51.1	Fill and bleed active body control (ABC)	Model 215, 220, 230	AR32.50-P-0021N
52.1	Fill and bleed power steering pump (30)	Model 215, 220, 230	AR46.30-P-0010N
		Model 211	AR46.30-P-0010P
53	Inspecting cooling system for leaks		AR20.00-P-1010RVK
	Risk of accident due to vehicle starting off 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
54	Check for leaks with engine running
55	Read out fault memory	When the work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. The stored faults may be caused by removed cables during installation or test operations as well as by simulation.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
56	Carry out function check

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	Engine 113.990
BA01.45-P-1003-01B	Oil drain screw to oil pan	M14	Nm	30	30	30

FUEL DISTRIBUTOR

Number	Designation		Engine 113.992/993/995	Engine 113.990/991
BA07.52-P-1001-01A	Fuel feed line to fuel distributor	Nm	38	38

OIL FILTER

Number	Designation		Engine 113.992/995	Engine 113.990/991/993
BA18.20-P-1003-01D	Bolt, oil line to oil filter housing	Nm	10	9
BA18.20-P-1004-01D	Bolt for oil line bracket	Nm	10	10

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 113.991 in model 215/220	Engine 113.990 in model 211
BA22.10-P-1003-01L	Bolt, rear engine crossmember to body	Nm	40	40

ENGINE MOUNTS, ENGINE SUPPORTS

Number	Designation		Engines 112, 113 in model 230
BA22.10-P-1003-01X	Bolt, rear engine crossmember to body	Nm	40

AIR CONDITIONING SYSTEM

Number	Designation		Model 230	Model 211	Model 215	Model 220
BA83.30-P-1010-01A	Suction line separation point to spring tower	Nm	8	-	10	10
BA83.30-P-1011-01A	Pressure and hot gas line on capacitor	Nm	8	8	10	10

POWER STEERING PUMP

Number	Designation		Model 211 with engine 112, 113
BA46.30-P-1002-01M	Banjo bolt, high pressure expansion hose to power steering pump	Nm	45

ENGINE LUBRICATION

Number	Designation			Engine 113.944/980/981/984/986/991	Engine 113.987/988/990/992/993/995
BF18.00-P-1001-01H	Engine oil	Filling capacity with oil filter	Liters	7.5	8.5
		Filling capacity without oil filter	Liters	-	8.0
		Specifications for Operating Fluids	Sheet	-	-
			Sheet	-	-
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A

COOLING SYSTEM

Number	Designation			Engine 113.992/995 in model 230	Engine 113.990	Engine 113.991 in model 215
BF20.00-P-1001-02K	Cooling system	Total filling capacity	Liters	≈ 13.0	≈ 1 3,2	≈ 1 4,5
		Capacity of anticorrosion/antifreeze agent down to -37°C	Liters	≈ 6.5	≈ 6.6	≈ 7.3
		Filling capacity of anticorrosion/antifreeze down to -45°C	Liters	≈ 7.3	≈ 7.3	≈ 8
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A	BB00.40-P-0310-01A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0325-00A	BB00.40-P-0325-00A	BB00.40-P-0325-00A

COOLING SYSTEM

Number	Designation			Engine 113.986/991 in model 220
BF20.00-P-1001-02K	Cooling system	Total filling capacity	Liters	≈ 13.5
		Capacity of anticorrosion/antifreeze agent down to -37°C	Liters	≈ 6.8
		Filling capacity of anticorrosion/antifreeze down to -45°C	Liters	≈ 7.4
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0325-00A

AIR CONDITIONING SYSTEM/AUTOMATIC AIR CONDITIONING

Number	Designation			Model 230	Model 211	Model 220 without rear air conditioning system
BF83.00-P-1001-01A	Capacity air conditioning system/automatic air conditioning	Refrigerant R12	g	-	-	-
		Refrigerant R134 a	g	920	950	950
		Specifications for Operating Fluids	Sheet	BB00.40-P-0361-00A	BB00.40-P-0361-00A	BB00.40-P-0361-00A

AIR CONDITIONING SYSTEM/AUTOMATIC AIR CONDITIONING

Number	Designation			Model 215	Model 220 with rear air conditioning system
BF83.00-P-1001-01A	Capacity air conditioning system/automatic air conditioning	Refrigerant R12	g	-	-
		Refrigerant R134 a	g	950	1050
		Specifications for Operating Fluids	Sheet	BB00.40-P-0361-00A	BB00.40-P-0361-00A

REFRIGERANT COMPRESSOR

Number	Designation			Refrigerant compressor 7SEU16C in model 230	Refrigerant compressor 7SEU16C in model 211	Refrigerant compressor 7SE16 in Model 215
BF83.55-P-1005-01A	Additional oil filling capacity when replacing receiver/drier	Compressor oil	cm³	10	10	10
BF83.55-P-1005-01A		Specifications for Operating Fluids	Sheet	BB00.40-P-0362-00A	BB00.40-P-0362-00A	BB00.40-P-0362-00A

REFRIGERANT COMPRESSOR

Number	Designation			Refrigerant compressor 7SE16 in model 220
BF83.55-P-1005-01A	Additional oil filling capacity when replacing receiver/drier	Compressor oil	cm³	10
BF83.55-P-1005-01A		Specifications for Operating Fluids	Sheet	BB00.40-P-0362-00A

Fig 5: Identifying Bracket (112 589 00 62 00)

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

Fig 7: Identifying Set Of Stop Plugs (129 589 00 91 00)

Fig 8: Identifying Hand Pump (210 589 00 71 00)