Remove/install engine

AR01.10-P-2400C

Remove/install engine

16.3.12

11.8.08

Perform default initialization - added

Operation step 42

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of 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



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Remove engine trim panel

2

Check rear engine lifting eyes for marking

 Engine suspension lugs without identification must be replaced.



Rear lifting eyes of engine reinforced

BT01.00-P-0001-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only pour liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

3

Disconnect battery ground line

 The battery is located below the rear seat.

AR54.10-P-0003A

 Installation: After connecting the ground cable, read out diagnostic trouble code memory, encode radio and normalize power windows.

Vehicles with stationary heater: adjust time display on stationary heater.



Notes on battery

AH54.10-P-0001-01A

4

Remove engine compartment paneling

AR61.20-P-1105AB

 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.

AS20.00-Z-0001-01A

5

Drain coolant at radiator

AR20.00-P-1142HA



Notes on coolant

AH20.00-N-2080-01A

6

Drain/collect engine oil

 Installation: Replace sealing ring of oil drain screw.



*BA01.45-P-1003-01B



*BF18.00-P-1001-01H

7

Remove viscous fan (1)

 Right-hand thread!

AR20.40-P-5660C

8

Remove fan shroud (2)

 On vehicles fitted with suction fan, separate the plug connection of the suction fan before removing the fan shroud.

9

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

10

Remove air filter housing (7).

11

Remove resonance tube (8) with resonance unit (9)

See "Remove hot film mass air flow sensor with air intake pipe".

AR07.07-P-1454A

 Disconnect plug connection for hot film mass air flow sensor (HFM) for this operation step and

Unscrew resonance pipe at cylinder head cover.

 The resonance pipe is attached at the rear at intake manifold with a plastic plate.

Do not damage plastic strap.

12

Detach coolant lines (18, 19) at coolant pump

13

Detach coolant line (20) at thermostat housing

14

Detach vacuum line (5) from brake booster at rear of intake manifold

15

Extract oil from power steering expansion reservoir



*112589007200

16

Detach return flow and pressure line to power steering pump (15)

 Seal connections!



*129589009100



*BA46.30-P-1002-01A



*BA46.30-P-1003-01A

17

Detach vacuum line (6) at intake manifold

 Danger!

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

18

Disconnect fuel line (4) at fuel distributor

 Release fuel pressure through service valve!

Collect fuel.



*BA07.52-P-1001-01A



*119589046300

19

Detach coolant line (17)

20

Disconnect engine wiring harness

AR01.00-P-2410K

21

Remove poly-V belt (3)

 Installation: Lock tensioning device with a drift or pin (diameter 5 mm).

AR13.22-P-1202BA

22

Detach connection hoses (23, 24) at oil lines (21, 22) and fit together with connection piece (25)

 Seal connections!



*129589009100



Connection fitting for automatic oil pipes

WF58.50-P-2020-01A

23

Unscrew refrigerant compressor from timing case cover

 Attach refrigerant compressor to bottom of engine compartment with lines connected.



*BA83.55-P-1001-01A

24

Detach exhaust system (10) at exhaust manifold

 Installation: On vehicles with engine damage it is necessary to inspect the exhaust system for swarf before installing it and to remove any swarf present, otherwise damage to the catalytic converter system may occur.



*BA14.10-P-1002-01B

25

Remove bracket (10a) for exhaust system (10)

Support exhaust system for this Operation step.

 Installation: Install new nuts.

26

Detach vibration damper at transmission below propeller shaft (11)

27

Take off propeller shaft (11) at transmission



*BA41.10-P-1001-01A

28

Release cable for parking shift lock (14)

AR27.60-P-0500-05B

29

Detach shift rod from transmission

30

Take off front wheels



Remove/install wheels

AP40.10-P-4050Z

31

Remove drive shafts (26)

 Pull drive shafts off front axle drive!

AR33.30-P-0620A

32

Remove engine crossmember (12)

 Support transmission for this operation step!



*BA22.10-P-1003-01L



*BA22.10-P-1002-01L

33

Unscrew screw/bolts (13) of front engine mounts at front axle carrier



*BA22.10-P-1001-01L

34

Disconnect refrigerant compressor connector

35

Detach power steering pump ground line (15)

36

Hang engine hoist in motor suspension lugs

37

Lower engine towards the rear and lift out

38

Install in the reverse order

39

Inspect cooling system for leaks

 When 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

 Danger!

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

40

Check oil level in transmission and correct if necessary

AR27.00-P-0100AC

41

Check for leaks with engine running

42

Perform default initialization.

For vehicles with ME 2.8 injection system after replacing the engine

 Connect STAR-DIAGNOSIS and select menu item for control unit adaptations in ME-SFI [ME] control unit.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

43

Read out fault memory and erase

 Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work: 

Diagnosis Manual Volume 2, Index 0: connection and use of test equipment

44

Check chassis alignment and adjust if necessary

AR40.20-P-0322E

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

BA01.45-P-1003-01B

Oil drain screw on oil pan

M14

Nm

30

Number

Designation

Engine
112 except
112.945/951/
960/961

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

Number

Designation

Engine
112 except 112.951 /
976

BA14.10-P-1002-01B

Flange connection, exhaust manifold/front exhaust pipes

Nm

20

Number

Designation

Engine
112.921/941,
113.940
in model 210.081/
082/083/281/
282/283

BA22.10-P-1001-01L

Screw/bolt, front engine mount to front axle carrier

Nm

35

BA22.10-P-1002-01L

Screw/bolt, rear engine mount to rear engine crossmember

Nm

35

BA22.10-P-1003-01L

Screw/bolt, rear engine crossmember to body

Nm

40

Number

Designation

Model
210

BA41.10-P-1001-01A

Self-locking nut, flexible coupling to transmission or front propeller shaft

M10

Nm

40

M12

Nm

60

Number

Designation

Model 210.061/062/063/
065/070/074/
081/082/083/
261/262/263/
265/270/274/
281/282/283/
663

BA46.30-P-1002-01A

Return line to power steering pump

Nm

2

BA46.30-P-1003-01A

High-pressure expansion hose to power steering pump

M141.5

Nm

-

M161.5

Nm

45

Number

Designation

Engine
112, 113
in model 202, 208, 210

BA83.55-P-1001-01A

Screw/bolt, refrigerant compressor to bracket

Nm

20

Number

Designation

Engine
112 (shortened maintenance interval)
except
112.916/953/975

Engine
112 (maximum maintenance interval)
except
112.916/953/975

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liters

8.0

8.0

Filling capacity without oil filter

Liters

7.5

7.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0229-01A

-

Sheet

BB00.40-P-0229-03A

-

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A