AR20.40-P-5000PV | Remove/install electric fan | 3.11.09 |
ENGINES 112.912 in MODEL 203.061 /261, 209.361 /461 with TRANSMISSION 716.6, 722.6
ENGINES 112.946 in MODEL 203.064 /264 /764 with TRANSMISSION 722.6
ENGINES 112.961 in MODEL 203.065 /265 with TRANSMISSION 722.6
ENGINES 113.968 in MODEL 209.375 /475 with TRANSMISSION 722.6
ENGINES 113.987 in MODEL 209.376 /476 with TRANSMISSION 722.636
ENGINES 112.955 in MODEL 209.365 /465 with TRANSMISSION 722.618
ENGINES 112.916 in MODEL 203.081 /281
ENGINES 112.953 in MODEL 203.084 /284
P20.40-2021-09
1 Engine suction fan ducts
2 Air cleaner housing
3 Plug connection
4 Audible warning device
5 Power steering hydraulic line
11 Hood release cable
12 Retaining clips
13 Coolant line
6 Bolt
7 Front end crossmember
8 Bolts
9 Retaining pin
10 Bolts
P20.40-2022-09
14 Retaining clip
15 Plug connection for right hood lock
16 Clamp
19 Rubber mounts
M4/7 Engine and AC electric suction fan with integrated control
17 Shackles
18 Supports
P20.40-2041-01
Model 203 with 4MATIC
20 Bracket of oil line rack-and-pinion steering
21 Bracket of oil line level control
Modification notes
| Remove/install | ||
1 | Remove engine suction fan ducts (1) upstream of air filter housing (2) | ||
2 | Unscrew bracket of oil line rack-and-pinion steering (20) at front end | Model 203 with 4MATIC | |
3 | Unscrew bracket of oil line level control (21) at timing case | Model 203 with 4MATIC and level control | |
4 | Disconnect connector (3) of the electric suction fan engine and AC with integrated control (M4/7) | ||
5 | Remove horn (4) | Unplug contact of audible warning device. | |
6 | Unscrew bolts of steering oil cooler to front end crossmember (7) | Two bolts. | |
7 | Detach hydraulic line of power steering (5) at front end crossmember (7) | ||
8 | Take off front end crossmember (7) at front crossmember. | Unscrew bolts (8). | |
9 | Remove bolts (10) at front end crossmember (7) on right and left. | ||
10 | Detach hood cable (11) | ||
11 | Detach retaining clips (12) of air ducting | ||
Danger! | Risk of injury to skin and eyes caused by scalding from 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. | |
12 | Drain coolant | Model 209 with engine 113 | |
| Notes on coolant | All engines | |
13 | Push coolant line (13) out of fixture | ||
14 | Remove cable ties at front end crossmember (7) | ||
15 | Disconnect plug connection of hood lock on right (15) | ||
16 | Detach connector from Distronic radar sensor | with code (219) Distronic | |
17 | Remove front end crossmember (7) together with hood cables | If rubber mounts (19) are firmly attached in the radiator, do not pull front end crossmember (7) upwards with force, but unscrew retaining pin (9) on right and left. Press together retaining bracket (14) of radiator on right and left, then unhook front end crossmember (7) and remove. | |
18 | Detach top coolant line at radiator | Model 209 with engine 113 | |
Use a screwdriver to push back the clip until it latches. | |||
Installation: Replace O-ring of coolant line. | |||
19 | Press clamp (16) on right and left | At the same time take out electric suction fan engine and AC with integrated control (M4/7) toward top. | |
20 | Take out engine and air conditioning electric suction fan with integrated control (M4/7) toward top | Installation: Ensure that plates (17) of electric suction fan engine and AC with integrated control (M4/7) are seated in supports (18) of radiator on right and left. | |
21 | Install in the reverse order | ||
22 | Carry out operational check of hood lock | ||
23 | Inspect gaps on hood | If required, adjust gap dimension. See: | |
Model 203.0 | |||
Model 203.2 | |||
Model 203.7 | |||
Model 209.3 | |||
Model 209.4 | |||
Feeler gauge | |||
24 | Check / adjust sensor setting of Distronic (DTR) | With code (219) Distronic | |
25 | Read out fault memory and erase | After work is complete, faults stored in the fault memory must be processed and erased. The stored faults can be caused by removed cables during installation or test operations, as well as by simulation. | |
| Connect STAR DIAGNOSIS and read out fault memory | ||
STAR DIAGNOSIS diagnosis system |
Test values for gap dimensions on hoods, doors and lids
Number | Designation | Model | Model | |||
BE60.00-P-1001-01E | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3.5 (1) | 3.5 (1) |
Engine hood to headlamp | Dimension "R" | mm | 4 (-0.5/+1.5) | 4 (-0.5/+1.5) | ||
Engine hood to bumper | Dimension "D" | mm | - | - | ||
See picture | ||||||
Test values for gap dimensions on hoods, doors and lids
Number | Designation | Model | |||
BE60.00-P-1001-01E | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3.6 (1) |
Engine hood to headlamp | Dimension "R" | mm | 4 (0.5) | ||
Engine hood to bumper | Dimension "D" | mm | 5 | ||
See picture | |||||
Test and adjustment values for gap dimensions
Number | Designation | Model | Model | |||
BE60.00-P-1001-01G | Gap dimension | Engine hood to fender | Dimension "A" | mm | 3.5 (0.5) | 3 (1) |
Engine hood to headlamp | Dimension "B" | mm | 3.5 (0.5) | 4 (0.5) | ||
Engine hood to bumper | Dimension "C" | mm | 4 (0.5) | 5 (0.5) | ||
See picture | ||||||
Feeler gauge
129 589 03 21 00
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