ar0110p2400a

Remove/install engine

Type ar · topic 01.10 · version 0119 · 2006-07-26

Applies to: ENGINE 111 in MODEL 124 ENGINE 111.920 /921 /941 /945 /961 /974 in MODEL 202 ENGINE 111.944 /945 /975 in MODEL 208 ENGINE 111.942 /970 in MODEL 210

Where it sits

Function group 1 Engine › 01 Complete engine, crankcase ventilation, cylinder head, crankcase › 01.10 Complete engine — Series 124 · Series 202 · Series 208 · Series 210

EinPAS 15 Engine › 15.15 Combustion engine, complete/engine housing/crank assembly › 15.15.15 internal combustion engine, complete — Series 124 · Series 202 · Series 208 · Series 210

Also applies to engines/gearboxes: 111 ***, 111 920, 111 921, 111 941, 111 942, 111 944, 111 945, 111 961, 111 970, 111 974, 111 975

AR01.10-P-2400A

Remove/install engine

24.10.05

ENGINE 111 in MODEL 124

ENGINE 111.920 /921 /941 /945 /961 /974 in MODEL 202

ENGINE 111.944 /945 /975 in MODEL 208

ENGINE 111.942 /970 in MODEL 210

Remove/install engine

P01.10-0223-09

Remove/install engine

P01.10-0224-06

Shown on model 202

50 Purge valve on engine with PMS injection system

82 Vacuum line

B Purge valve line

B1 Purge control valve line on engines with HFM injection system

C Purge valve line on engine with PMS injection system

N3/6 PMS control unit

Y58/1 Purge control valve on engines with HFM injection system

Remove/install engine

P01.10-0225-06

Shown on model 202

4 Brake unit vacuum line

17/2 Fuel pipe

17/3 Fuel pipe

19 Vacuum line

Y3/3 Upshift delay switchover valve in model 202, 210 with automatic transmission 722.4

Y4 Switchover valve, 2nd transmission mode
Model 202, 210 with automatic transmission 722.4

Remove/install engine

P01.10-0226-09

Remove/install

1

Remove engine compartment covering (16)

AR61.20-P-1105AB

2.1

Remove viscous fan clutch (13)

Left-hand thread

Model 202, 210 with Code 580/581 AC system or Automatic AC until around 09.96

Model 208

AR20.40-P-5660A

3

Remove radiator (12)

AR20.20-P-3865A

4.1

Remove hot film mass air flow sensor (14)

Vehicles with hot film mass air flow sensor

AR07.07-P-1453D

5

Remove air filter transverse pipe (15)

6.1

Remove top part of air filter (11)

Model 202, 208, 210

7.1

Remove poly-V belt (20)

with air conditioning

AR13.22-P-1202A

8.1

Attach guard plate at condenser

Guard plate for radiator / condenser

if AC (code 580, 581) fitted

WF58.50-P-0110-01A

9

Disconnect engine wiring harness

Model 124

AR01.00-P-2410A

Model 202

AR01.00-P-2410B

Model 208

AR01.00-P-2410L

Model 210 up to 02.97

AR01.00-P-2410C

Model 210 as of 03.97

AR01.00-P-2410CA

10.1

Pull out vacuum line (82) from PMS control unit (N3/6)

Vehicles with PMS injection system

11.1

Pull out lines at purge valve (50)

Vehicles with PMS injection system

12.1

Pull out line (B1) at purge switchover valve (Y58/1).

Vehicles with HFM, ME-SFI injection system

13

Detach throttle control cable

Danger!

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

14

Disconnect fuel lines (17/2), (17/3)

Open tank lock

Model 124: Disconnect fuel lines at fuel distributor, replace sealing rings.

Model 202, 208, 210: Disconnect fuel lines at line fittings.

15

Disconnect vacuum lines (4) at intake manifold 19

Model 124, 208, 210: Disconnect vacuum line (4) to brake unit at intake manifold.

Model 202: Disconnect vacuum line (4) to brake unit at brake unit.

16.1

Disconnect vacuum lines at the switchover valves (Y3/3, Y4)

Automatic transmission 722.4

17

Unscrew lines (26, 27, 28, 29) of power steering pump

Before disconnecting the lines, extract oil at reservoir.
Installation: With level control (Code 217bn)

AR46.30-P-0500A

Emptying and filling pressure oil system

AR32.30-P-0630A

18

Disconnect coolant hoses (5, 6) at cylinder head and coolant pump

*WH58.30-Z-1001-06A

*WH58.30-Z-1002-06A

19.1

Unscrew AC compressor (7) (arrows), secure

If AC (code 580, 581) fitted:
Attach AC compressor at bottom in side of engine compartment with piping connected.

20

Drain coolant

at crankcase

AR20.00-P-1142HG

21

Unclip shift rods at transmission

Manual transmission

AR26.10-P-0020A

Automatic transmission

AR27.10-P-0500A

22.1

Disconnect clutch line at slave cylinder

Manual transmission

AR25.20-P-0150A

23

Loosen clamping nut (41) of propeller shaft (42)

Models 124, 202: clamping nut (41) not required as of 01/95, replaced by sliding piece.

AR41.10-P-0050EA

24

Unbolt propeller shaft (42) at transmission

AR41.10-P-0050EA

25

Remove rear engine mount

Model 124

AR22.10-P-1160HA

Model 202, 208, 210

AR22.10-P-1160HB

26.1

Dismount electrical lines and speedometer shaft at transmission

Model 124

27

Unscrew engine mount at body and front axle carrier at front

AR22.10-P-1260HA

28

Raise engine, remove

Model 202: Clip engine hoist (38) into both engine lifting eyes

*WE58.40-Z-1012-11A

Model 208, 210: Remove engine with removal fixture

AR01.10-P-2400-01A

Engine supporting shackle

*WH58.30-Z-1002-07A

Hook mount

*WH58.30-Z-1003-07A

29

Install in the reverse order

30

Read fault memory, erase.

AD00.00-P-1000AZ

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-1002-07A

Engine carrier arm

WH58.30-Z-1003-07A

Hook mount

Workshop equipment

WE58.40-Z-1012-11A

Load regulator (engine hoist), self-locking

Referenced documents