Remove/install engine

AR01.10-P-2400CA

Remove/install engine

16.3.12

11.8.08

Perform default initialization - added

Operation step 45

 

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 in the right of the engine compartment.

AR54.10-P-0003A



Notes on battery

AH54.10-P-0001-01A

 Installation: After connecting, read out fault memory, encode radio and normalize power windows.

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

4

Remove air guide (23)

Engine 113.942

 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

 Remove coolant pump line(16) from coolant pump.

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)

Except model 163.174 with engine 113.981 and 163.175 with engine 113.965

AR20.40-P-5660C

 Right-hand thread!

8

Remove fan shroud (2)

 Remove screw/bolts at bottom of fan shroud

9

Remove electric fan

Model 163.174 with engine 113.981 and 163.175 with engine 113.965

AR20.40-P-5000GH

10

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

11

Remove expansion reservoir (13)

12

Remove air filter housing (7).

13

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

 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.

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

Engine 112.942/ 970

AR07.07-P-1454A

ENGINE 113.942/ 965/ 981

AR07.07-P-1454MV

14

Remove coolant pump line(15) from coolant pump.

15

Remove thermostat housing coolant line  (17) from thermostat housing

16

Remove radiator

ENGINE 113.942/ 965/ 981

AR20.20-P-3865HC

17

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

18

Extract power steering pump (19) oil



*210589007100

19

Detach return flow line and pressure line of power steering pump (19)

 Seal connections!



*129589009100



*BA46.30-P-1002-01A



*BA46.30-P-1003-01A

20

Remove regeneration vacuum line (6) from intake pipe

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

21

Disconnect fuel line (4)

 Release fuel pressure through service valve!

Collect fuel.



*BA07.52-P-1001-01A



*119589046300

22

Detach coolant line (14)

23

Disconnect engine wiring harness

AR01.00-P-2410V

24

Remove poly-V belt (3)

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

Model 163.154/ 157/ 172

AR13.22-P-1202B

Model 163.174 /175

AR13.22-P-1202BA

25

Disconnect refrigerant compressor connector

26

Remove refrigerant compressor

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



*BA83.55-P-1001-01A

27

Remove left inner fender (24)

ENGINE 113.942/ 965/ 981

AR88.10-P-1300GH

28

Remove shield (25)

ENGINE 113.942/ 965/ 981

29

Detach exhaust system (11) 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

30

Detach exhaust bracket (12)

Support exhaust system for this operation step.

Installation: Install new nuts.

31

Unscrew torque converter (20) from starter ring gear (21)

Installation: The mounting points (arrows, black) of the torque converter must be flush with the three recesses (arrows, white) in the starting ring gear.



*BA27.20-P-1002-01C

32

Disconnect left O2 sensor connector before catalytic converter (G3/3x1) and right O2 sensor connector before catalytic converter (G3/4x1) from transmission

 Remove cable ties!

33

Unscrew starter

 Do not disconnect electrical lines.



*BA15.30-P-1003-01A

34

Unscrew screw/bolts on transmission bell

Engine 112.942 /970:

Do not unscrew two top screw/bolts at transmission bell.

Engine 113.942 /965 /981:

Do not unscrew two bottom screw/bolts at transmission bell.



*BA27.40-P-1008-01A

35

Unscrew nuts (18) for engine mount

 Before unscrewing left engine mount, press out oil line for power steering out of fixture.



*BA22.10-P-1001-01L

36

Unscrew oil filler pipe (transmission) on right cylinder head cover

37

Hang engine hoist in motor suspension lugs

 Use engine removal device!

38

Raise engine

 Ensure that engine and its detachable components are not lying against the body!

39

Insert transmission support (22)

 The transmission support is inserted onto crossmember and into recess of transmission.

 The transmission support prevents the torque converter being pulled out. At the same time, the transmission is fixed in place with the transmission support when installing the engine.

40

Unscrew two top screw/bolts (engine 112) or two bottom screw/bolts (engine 113) of transmission bell

Ensure that engine does not hit at front against radiator or condenser damaging them

41

Pull engine out toward front and lift out

42

Install in the reverse order

43

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

44

Check for leaks with engine running

45

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

46

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

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

Engine
113.940/941/
942/943/944/
945/946/960/
961/962/963/
965/967/968/
969/980/981/
982/984/986/
992/995

BA01.45-P-1003-01B

Oil drain screw on oil pan

M14

Nm

30

30

Number

Designation

Engine
112 except
112.945/951/
960/961

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/988

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

38

Number

Designation

Engine
112 except 112.951 /
976

Engine 113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/992/993/
995

BA14.10-P-1002-01B

Flange connection, exhaust manifold/front exhaust pipes

Nm

20

20

Number

Designation

Engine
112 except 112.951, 113.94/
96/98

BA15.30-P-1003-01A

Screw/bolt connecting starter to crankcase

Nm

42

Number

Designation

Engine 112.942/970
113.942/965/981
in model 163.154/157/
172/174/175

BA22.10-P-1001-01L

Screw/bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Transmis-sion 722.6
except
722.648

BA27.20-P-1002-01C

Screw/bolt, torque converter to drive plate

Straight threaded connection

M8

Nm

42

Angled threaded connection

Stage 1

Nm

4

Stage 2

Nm

30

Stage 3

°

90

Number

Designation

Transmission
722.660/661/662/663/666/673/674

BA27.40-P-1008-01A

Screw/bolt, automatic transmission to engine

M1040

Nm

40

M1090

Nm

40

M12

Nm

-

Number

Designation

Model 163.136

Model
163.128/154/157/
172/174/175

BA46.30-P-1002-01A

Return line to power steering pump

Nm

2

2

BA46.30-P-1003-01A

High-pressure expansion hose to power steering pump

M141.5

Nm

-

-

M161.5

Nm

45

45

Number

Designation

Engine
111, 112, 113, 612, 628
in model 163

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

Number

Designation

Engine
113.940/941/
942/943/960/
961/962/969/
982 (shortened maintenance interval)

Engine
113.940/941/
942/943/960/
961/962/969/
982 (maximum maintenance interval)

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liters

8.0

8.0

Filling capacity without oil filter

Liters

-

-

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

Number

Designation

Engine
113.963/965/968
(shortened maintenance interval)

Engine
113.963/965/968 (maximum maintenance interval)

Engine 113.944/980/981/984/986/991

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liters

7.5

7.5

7.5

Filling capacity without oil filter

Liters

7.0

7.0

-

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

BB00.40-P-0229-05A