Remove/install engine

AR01.10-P-2400CB

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 screw/bolts

AH00.00-N-0001-01A

1

Remove engine cover or air filter

 Remove engine trim panel or air filter by lifting vertically up and off the cylinder head covers.

 The air filter is integrated into the engine cover in model 129, 202.093/033, 208.370/374/470 and 210.274/074

2

Check rear engine lifting eyes for marking

 Motor 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

 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.

AR54.10-P-0003A



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

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

8

Remove viscous fan (1)

All except model 208.365/465 with engine 112.

AR20.40-P-5660C

 Right-hand thread!

9

Remove fan shroud (2)

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

10

Remove air filter housing (7).

All except model 129, 202.033/093, 208.370/374/470, 210.074/274

11

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

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

All except model 129, 202.033/093, 208.370/374/470/474, 210.074/274, 202.088, 210.062/262/083/283

AR07.07-P-1454A

Model 202.088, 210.062/262/083/283

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

Remove hot film mass air flow sensor with air intake pipe

Model 129, 202.033/093, 210.074/274, 208.370/374/470

AR07.07-P-1454AG

Model 208.474

13

Detach coolant lines (18, 19) at coolant pump

14

Detach coolant line (20) at thermostat housing

15

Detach coolant line at top of expansion reservoir

Model 208, 202

16

Remove radiator

MODEL 210, 208, 202 with ENGINE 113

AR20.20-P-3865HD

Model 129 with engine 113

AR20.20-P-3865AV

17

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

18

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

19

Extract oil from power steering expansion reservoir



*210589007100

20

Detach power steering pump ground line (15)

21

Detach return flow and pressure lines of power steering pump (15)

 Seal connections!



*129589009100



*BA46.30-P-1002-01A



*BA46.30-P-1003-01A

22

Detach vacuum line (6) at intake manifold

 Model 129

Detach vacuum line directly at purge control valve.

 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

23

Disconnect fuel line (4) at fuel distributor

 Release fuel pressure via service valve and collect fuel!



*BA07.52-P-1001-01A



*119589046300

24

Detach coolant line (17)

 In model 202.093/033 an additional coolant line is attached to the right cylinder head.

The coolant line at the right cylinder head leads to an external transmission oil cooler located on the right, behind the front apron. The routing of the coolant line to the left cylinder head is the same as that of production vehicles.

25

Disconnect engine wiring harness

Model 210, 208, 202

AR01.00-P-2410K

Model 129

AR01.00-P-2410AV

26

Remove poly-V belt (3)

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

Model 129, 210 with engine 113, 208 with engine 113, 202 with engine 113.

AR13.22-P-1202B

Model 210 with engine 112, 208 with engine 112, 202 with engine 112.

AR13.22-P-1202BA

27

Disconnect connector from refrigerant compressor

28

Unscrew refrigerant compressor from timing case cover

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



*BA83.55-P-1001-01A

29

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

30

Disconnect and unhook connectors for O2 sensors left (G3/3x1) and right (G3/4x1)

Model 202, 208

31

Remove bracket (10a) of exhaust system

 All except model 129, support exhaust system.

 Installation: Install new nuts.

32

Unscrew clutch slave cylinder

Model 210, 202, 129 with manual transmission.

AR25.20-P-0150A

 Do not disconnect line.

33

Take off propeller shaft (11) at transmission



*BA41.10-P-1001-01A

34

Release cable for parking shift lock (14)

If automatic transmission fitted

AR27.60-P-0500-05B

35

Detach shift rod from transmission

36

Remove rear engine crossmember (12) at transmission

 For this operation stepsupport transmission.



*BA22.10-P-1002-01L



*BA22.10-P-1003-01L

37

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



*BA22.10-P-1001-01L

38

Press pressure line of level control out of holders on bottom part of oil pan

Model 129

39

Hang engine hoist in motor suspension lugs

 On model 210 with engine 113 and model 208 with engines 112, 113 use the engine removal fixture!

40

Lower engine towards the rear and lift out

41

Install in the reverse order

42

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

43

Check oil level in automatic transmission and correct if necessary.

AR27.00-P-0100AC

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
112.910/920,
113.944
in model 202.026/029/
033/086/089/
093

Engine
112.911/914/921/941,
113.940/980
in model 210.061/062/
063/065/070/074/261/
262/263/265/270/274

BA22.10-P-1001-01L

Screw/bolt, front engine mount to front axle carrier

Nm

35

35

BA22.10-P-1002-01L

Screw/bolt, rear engine mount to rear engine crossmember

Nm

30

30

BA22.10-P-1003-01L

Screw/bolt, rear engine crossmember to body

Nm

40

40

Number

Designation

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

Engine 112.923/943,
113.961
in model 129.059/
064/068

BA22.10-P-1001-01L

Screw/bolt, front engine mount to front axle carrier

Nm

35

25

BA22.10-P-1002-01L

Screw/bolt, rear engine mount to rear engine crossmember

Nm

35

30

BA22.10-P-1003-01L

Screw/bolt, rear engine crossmember to body

Nm

40

40

Number

Designation

Engine
112.940,
113.943/984
in model 208.365/
370/374/465/
470

Engine
112.915
in model 202.088

BA22.10-P-1001-01L

Screw/bolt, front engine mount to front axle carrier

Nm

35

35

BA22.10-P-1002-01L

Screw/bolt, rear engine mount to rear engine crossmember

Nm

30

30

BA22.10-P-1003-01L

Screw/bolt, rear engine crossmember to body

Nm

40

40

Number

Designation

Engine
113.984 in model 208.474

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

30

BA22.10-P-1003-01L

Screw/bolt, rear engine crossmember to body

Nm

40

Number

Designation

Model
129

Model
202

BA41.10-P-1001-01A

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

M10

Nm

40

40

M12

Nm

60

60

Number

Designation

Model
208

Model
210

BA41.10-P-1001-01A

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

M10

Nm

40

40

M12

Nm

60

60

Number

Designation

Model 129.059/
064/068

Model 202.026/029/
033/086/088/089/093

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

-

30

M161.5

Nm

45

40

Number

Designation

Model 208.365/370
374/465/ 470/474

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

2

BA46.30-P-1003-01A

High-pressure expansion hose to power steering pump

M141.5

Nm

-

-

M161.5

Nm

40

45

Number

Designation

Engine
112, 113
in model 129

Engine
112, 113
in model 202, 208, 210

BA83.55-P-1001-01A

Screw/bolt, refrigerant compressor to bracket

Nm

20

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)

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

BF18.00-P-1001-01H

Engine oil

Filling capacity with oil filter

Liters

8.0

8.0

7.5

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

BB00.40-P-0229-05A