Remove/install engine

AR01.10-P-2400CC

Remove/install engine

16.3.12

11.8.08

Perform default initialization - added

Operation step 41

 

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 air filter (2)

 Pull off air filter (2) vertically upwards from cylinder head cover.

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

All models except 463.241 with code 979

AR54.10-P-0003G

Model 463.241 with code 979

AR54.10-P-0003PV



Notes on battery

AH54.10-P-0001-01A

4

Remove underride guard (1)

 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

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 (3)

 Right-hand thread

AR20.40-P-5660C

8

Remove fan shroud (7)

AR20.40-P-6800V

9

Remove radiator (8)

 Disconnect connector (A).

AR20.20-P-3865GV

10

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

11

Disconnect engine wiring harness

AR01.00-P-2410GV

12

Detach coolant lines (9) from coolant pump

13

Remove hot film mass air flow sensor (B2/5) with air intake pipe

ENGINE 113.962

AR07.07-P-1454AG

14

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

15

Remove regeneration vacuum line (6) on intake pipe

16

Extract oil from power steering expansion reservoir



*210589007100

17

Detach return flow and pressure line (12, 13) of power steering pump (11)

 Seal connections!



*129589009100



*BA46.30-P-1001-01B

 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 via service valve and collect fuel!



*BA07.52-P-1001-01A



*119589046300

19

Detach coolant line (14)

20

Remove poly-V belt (15)

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

AR13.22-P-1202B

21

Detach connecting hoses (17) at oil lines (18)

 Seal connections!



*129589009100

22

Remove catalytic converters (16)

ENGINE 113.962

 Installation:

- Replace all nuts.

- Use emery cloth to remove combustion and corrosion residues at connection points of exhaust pipes.

- Install exhaust system free of stress.

- On vehicles with engine damage the catalytic converters must be checked for swarf before installing it and to remove any swarf present, otherwise damage to the catalytic converter system may occur.



*BA49.10-P-1002-01A

23

Unscrew shield (19) on right at frame

24

Unscrew engine mount (20) at frame



*BA22.10-P-1001-01K

25

Raise engine at front engine suspension lug

 When raising and lowering engine, ensure that

- shields are not jammed,

- no lines are overtensioned

- the engine and attached parts do not touch the body.

26

Unscrew refrigerant compressor from timing case cover

 Place refrigerant compressor to the side with lines connected.

 Disconnect plug connection at refrigerant compressor.



*BA83.55-P-1001-01A

27

Remove shield (22)

ENGINE 113.962

28

Remove front exhaust pipes (23)

ENGINE 113.962

 Disconnect connector for O2 sensor (G3/4x1).

 Installation:

- Replace all nuts.

- Use emery cloth to remove combustion and corrosion residues at connection points of exhaust pipes.

- Install exhaust system free of stress.

- On vehicles with engine damage the front exhaust pipes must be checked for swarf before installing it and to remove any swarf present, otherwise damage to the catalytic converter system may occur.



*BA49.10-P-1002-01A

29

Remove shield (19)

 Push engine slightly to the side if necessary.

30

Lower engine

 When raising and lowering engine, ensure that

- shields are not jammed,

- no lines are overtensioned, and

- the engine and attached parts do not touch the body.

31

Unscrew front exhaust pipes (23)

Engine 112.945

Right: disconnect exhaust system at

exhaust manifold.

Left: disconnect exhaust system at exhaust transverse pipe

pipe

 Installation:

- Replace all nuts.

- Use emery cloth to remove combustion and corrosion residues at connection points of exhaust pipes.

- Install exhaust system free of stress.

- On vehicles with engine damage the front exhaust pipes must be checked for swarf before installing it and to remove any swarf present, otherwise damage to the catalytic converter system may occur.



*BA49.10-P-1002-01A



*BA49.10-P-1003-01A

32

Unscrew propeller shaft (24) at transmission flange

 Installation: Replace screw/bolts for propeller shaft.



*BA41.10-P-1001-01B

33

Remove clamp (25) and detach shift rod (26) at transmission

34

Remove engine crossmember (27)

 Support transmission!

Remove engine crossmember and engine mount



*BA22.10-P-1006-01K



*BA22.10-P-1003-01K

35

Hang engine hoist in motor suspension lugs

36

Lower engine towards the rear and lift out

37

Install in the reverse order

38

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

39

Check oil level in automatic transmission and correct if necessary.

AR27.00-P-0100AC

40

Check for leaks with engine running

41

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

42

Read out fault memory and erase

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
112.945

BA07.52-P-1001-01A

Fuel feed line to fuel distributor

Nm

38

38

Number

Designation

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

Number

Designation

Engine 112.945, 113.962/982

BA22.10-P-1001-01K

Screw/bolt, front engine mount to frame

Nm

75

BA22.10-P-1003-01K

Screw/bolt, rear frame crossmember to frame

Nm

27

BA22.10-P-1006-01K

Rear engine mount to bracket

Stage 1

Nm

28

Stage 2

°

90

Number

Designation

Model
463

BA41.10-P-1001-01B

Screw/bolt, homokinetic propeller shaft to transmission flange

Nm

60

Number

Designation

Model 463.2
except model 463.202/222/
236/237/272/
273,
model 463.30/
320/321/324/
325/327/328/
33/34

BA46.30-P-1001-01B

High-pressure expansion hose to power steering pump

M14x1.5

Nm

30

M16x1.5

Nm

40

Number

Designation

Engines
112, 113
in model
463

BA49.10-P-1002-01A

Screw/bolt of flange connection to exhaust pipe

Nm

25

BA49.10-P-1003-01A

Screw/bolt, flange connection to crosspipe / exhaust system

Nm

25

Number

Designation

Engines
112, 113
in model 463

BA83.55-P-1001-01A

Screw/bolt, refrigerant compressor to bracket

Nm

23

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