Remove/install starter

AR15.30-P-7100Q

Remove/install starter

15.2.12

3.9.03

Check ring gear - added

Steps 13.1 and 13.2

 

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

 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 fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Deactivate easy entry/exit function for driver seat and steering wheel

In vehicles with driver seat, steering column and electrically adjustable outside mirror with memory code 275

 When easy entry/exit for the driver seat and steering wheel is activated, the seat will move into the memory position when the ignition is switched on or the driver door is opened and closed; thus the top frame can be damaged when the holding device is installed.

 Deactivation takes place via the instrument cluster. Select Individual Settings in the main menu and follow menu instructions.

2.1

Move the electrically adjustable steering column all the way out

In vehicles with driver seat, steering column and electrically adjustable outside mirror with memory code 275

2.2

Open lock of steering column and pull out steering column fully, close lock

In the case of a mechanically adjustable steering column

3

Rotate the steering wheel to the center position

 The front wheels must be in the straight-ahead position.

4

Lock steering wheel

 With a disengaged steering coupling (3) the steering wheel should not be twisted because the clock spring contact will be destroyed.

 Holding device

*129589012100

5

Disconnect ground line from battery

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q



Notes on battery

AH54.10-P-0001-01A

6

Detach lower engine compartment paneling

AR61.20-P-1105P

7

Detach refrigerant line

 Remove two bolts (1) and place refrigerant line to the side.

8

Remove steering coupling (3)

 Pull out bolt (2) and steering coupling (3) from steering shaft. Remove bolt (10) and remove. Pry off steering coupling (3) from rack-and-pinion steering.

 Bolt, steering coupling to steering shaft

*BA46.10-P-1001-01E

 Self-locking nut, steering coupling to rack-and-pinion steering

*BA46.10-P-1002-01E

9

Remove intake muffler (5)

 Remove bolts (4) of intake muffler (5) and pry off intake muffler (5).

 Intake muffler to supercharger

*BA09.50-P-1004-01C

10

Remove line at electrical connection circuit 50 (8) at starter (M1)

 Nut for connection circuit 50

*BA15.30-P-1002-01A

11

Detach lines on electrical connection for circuit 30 (9) on starter (M1)

 Nut for connection circuit 30

*BA15.30-P-1001-01A

12

Remove starter (M1)

 Remove bolts (7) and remove starter (M1) from bottom.

 Bolt connecting starter to crankcase

*BA15.30-P-1003-01A

13.1

Check ring gear at flywheel for wear and damage

When replacing starter (M1) on vehicles fitted with manual transmission

 Rotate engine at crankshaft in direction of rotation.

13.2

Check ring gear at the drive plate for wear and damage

When replacing the starter (M1) on vehicles fitted with automatic transmission

 Rotate engine at crankshaft in direction of rotation.

14

Install in the reverse order

 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

15

Carry out function check

16

Perform basic programming

Model 203

AR00.19-P-0200P

Model 209

AR00.19-P-0200Q

17

Read out fault memory and erase

 Stored faults which may be caused by assembly work, test work, removed lines or a simulation, must be processed and erased in fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
271

BA09.50-P-1004-01C

Intake muffler to supercharger

M6

Nm

9

Number

Designation

Engine
271

BA15.30-P-1001-01A

Nut, connection for circuit 30

Nm

14

BA15.30-P-1002-01A

Nut, connection for circuit 50

Nm

6

BA15.30-P-1003-01A

Bolt connecting starter to crankcase

Nm

40

Number

Designation

Model
203 except
203.081/
084/087/
092/281/
284/287/
292

Model
209

BA46.10-P-1001-01E

Bolt, steering coupling to steering shaft

Stage 1

Nm

30

30

Stage 2

°

-

-

BA46.10-P-1002-01E

Locking screw and steering coupling locknut to rack-and-pinion steering

Nm

25

24