i need help on this, steps, wis just information in general.

 

AR01.10-P-2400Q Remove/install engine 6.3.02
ENGINE 113.968 in MODELS 209.375 /475 with TRANSMISSION 722.633
ENGINE 113.987 in MODELS 209.376 /476 with TRANSMISSION 722.636
P01.10-2359-09
Shown on model 209


1 Move selector lever of automatic transmission
into Neutral a Danger! Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Pour battery acid only into suitable and appropriately marked containers.
AS54.10-Z-0001-01A

2 Disconnect battery ground cable AR54.10-P-0003Q p Notes on battery All models AH54.10-P-0001-01A

3 Remove air filter housing (1) and the two air intake pipes (2)
i Detach air filter housing (1) vertically upwards from the cylinder head covers. i Installation: Moisten slightly with sliding compound the rubber retainers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor (B2/5) in the air filter housing (1). Liquid lubricant (Naphtolen H) *BR00.45-Z-1003-06A

4 Remove suction-type fan AR20.40-P-5000PV

5 Remove poly V-belt AR13.22-P-1202PV

6 Remove hot film mass air flow sensor (B2/5) AR07.07-P-1454SV

7 Detach vacuum line (9) i Pull off vacuum line (9) from purge valve to intake manifold.

8 Detach vacuum line of brake booster at connection piece (10) of intake manifold
i To do this, press the two clamps (arrows) together and pull out the vacuum line.

9 Disconnect engine wiring harness AR01.00-P-2410PV
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 2
a Danger! Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.
No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel.
AS47.00-Z-0001-01A

10 Disconnect fuel line (8) at fuel rail i Release fuel pressure through service valve. Collect fuel. n Disconnect fuel feed line at fuel rail *BA07.52-P-1001-01A l Pressure hose *119589046300

11 Suction off oil from power steering expansion reservoir (7) of power steering pump (4)
l Hand pump *210589007100

12 Take off power steering return line (6) at power steering expansion reservoir (7) of power steering pump (4)
i Seal off the connections.
i Installation: Check condition of hose clamp and power steering return line (6), replace if necessary. n Return flow line at power steering pump *BA46.30-P-1004-01D l Set of plugs *129589009100

13 Detach power steering high pressure line (3) at power steering pump (4).
p Seal connections in order to prevent foreign matter from entering. i Installation: Replace O-ring of pressure line. n Banjo bolt of high pressure expansion hose to power steering pump
*BA46.30-P-1003-01D
l Set of plugs *129589009100

14 Detach ground cable (5) of power steering pump (4)

15 Remove engine compartment paneling AR61.20-P-1105P a Danger! Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from 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 bottles. Wear protective gloves, protective clothing and eye protection. AS20.00-Z-0001-01A

16 Drain the coolant from radiator AR20.00-P-1142PV p Notes on coolant All engines AH20.00-N-2080-01A

17 Drain and collect engine oil i Installation: Replace sealing ring of the oil drain screw. n Oil drain screw to oil pan *BA01.45-P-1003-01B j *BF18.00-P-1001-01H

18 Remove complete exhaust system (24) as of flange connection of exhaust manifold
p On vehicles with engine damage, it is necessary to inspect the front exhaust system for swarf before installing it. Remove any swarf present, otherwise damage to the catalytic converter system may occur. Engine 113.968 in model 209.375/475
Engine 113.987 in model 209.376 up to 23.4.04, 209.476
AR49.10-P-7000PV
Engine 113.987 in model 209.376 as of 24.4.04
AR49.10-P-7000AC
i Installation: Replace bolts. Inspect rivet nuts in exhaust manifold, replace if necessary.
Replace rivet bushes in exhaust manifold AR49.10-P-5531-01DA n Exhaust manifold flange connection and exhaust front pipes *BA14.10-P-1002-01B

19 Remove exhaust bracket (27) i Installation: Replace tapping plates and nuts. n Bolt, exhaust bracket to transmission *BA49.10-P-1007-01A n Self-locking nut to front exhaust pipe *BA49.10-P-1008-01A

20 Take off propeller shaft (17) at transmission n Self-locking nut, flexible coupling to transmission or front section of driveshaft *BA41.10-P-1001-01A

21 Detach selector lever rod (22) at transmission i Installation: Check fuse (21), replace if necessary.

22 Separate ground cable (20) from body
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 3


23 Remove rear engine mount (18) at engine crossmember (25)
i Rear engine mount (18) remains on the transmission. n Bolt of rear engine mount to rear engine crossmember
*BA22.10-P-1002-01L

24 Detach engine crossmember (25) from body i Only remove the four outer bolts of the engine crossmember (19), slacken the two middle ones by a 1/4 turn. n Bolt of rear engine crossmember to body *BA22.10-P-1003-01L

25 Unscrew bolts of front engine mount (23) at front axle carrier
n Bolt, front engine mount to front subframe *BA22.10-P-1001-01L

26 Detach refrigerant compressor (A9) iAttach refrigerant compressor (A9) to bottom of engine compartment with lines connected. n Screw for AC compressor on mount *BA83.55-P-1001-01A

27 Separate connector of refrigerant compressor (A9)

28 Detach top coolant hose (16) and bottom coolant hose (14) at radiator
i Push back clip until it latches in place, pull out coolant line. i Installation: Replace sealing rings of coolant lines .

29 Separate ATF line (13) from oil cooler p Seal connections in order to prevent foreign matter from entering. Push back clamp until it latches in place, pull out oil line. i Installation: Replace sealing rings of ATF lines (13). l Set of plugs *129589009100

30 Detach coolant line at expansion reservoir

31 Separate coolant feed line from expansion reservoir at connection of radiator hose (12)

32 Detach coolant line from connection of electric circulation pump (11)

33 Detach heating coolant line at radiator tank i Push back clip until it latches in place, pull out coolant line. i Installation: Replace sealing rings of coolant line.

34 Attach guard plate for radiator / condenser y Guard plate for radiator / condenser WF58.50-P-0110-01A

35 Hook the engine hoist into the engine lifting eyesk Engine hoist (self-locking) *WH58.30-Z-1001-07A

36 Support transmission with car jack.

37 Unbolt engine crossmember (25) from body i Unscrew the remaining two bolts of engine crossmember (19). n Bolt of rear engine crossmember to body *BA22.10-P-1003-01L

38 Lower engine towards the rear and lift out i Lower the support (car jack) below the transmission for this step. Tilt engine backward in stages using the engine hoist and move out to the front using the engine hoist.

39 Install in the reverse order

40 Bleed cooling system i Warm up the engine to normal operating temperature and set the temperature control of heating to warm.

41 Inspect cooling system for leaks p If new cylinder head gaskets are installed, warm up engine first of all to operating temperature otherwise complete filling of the engine with coolant is not assured.
AR20.00-P-1010P
42 Check engine oil level Engine 113.968 in model 209 AR18.00-P-3035-01CC Engine 113.988 in model 203 AMG AR18.00-P-3035-01PA a 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 engine Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts. AS00.00-Z-0005-01A

43 Check oil level in automatic transmission, correct if necessary AR27.00-P-0101P

44 Run engine and inspect for leaks

45 Perform basic programming AR00.19-P-0200Q
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 4

46 Read out fault memory and erase i Stored faults which may be caused by removal, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work. a Connect STAR DIAGNOSIS and read out fault
memory
AD00.00-P-2000-04A
STAR DIAGNOSIS diagnosis system *WE58.40-Z-1013-06A

47 Perform function check
n Oil pan
Number Designation Engine 113.940/941/ 942/943/944/ 945/946/960/ 961/962/963/ 965/967/968/ 969/980/981/ 982/984/986/ 992
Engine 113.987/ 988/991
BA01.45-P-1003-01B Oil drain screw to oil pan M14 Nm 30 30
n Fuel rail
Number Designation Engine 113.987
Engines 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
n Exhaust manifold
Number Designation Engines 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
Engine 113.987/ 988/990/ 991
BA14.10-P-1002-01B Flange connection, exhaust manifold and front exhaust pipes
Nm 20 20
n Engine mounts, engine supports
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 5
Number Designation Engine 113.968 in model 209
Engine 113.987 in model 209
BA22.10-P-1001-01L Bolt, front engine mounts to front axle carrier Nm 35 35
BA22.10-P-1002-01L Bolt of rear engine mount to rear engine cross member
Nm 30 30
BA22.10-P-1003-01L Bolt of rear engine crossmember to body Nm 40 40
n Driveshaft
Number Designation Model 209
BA41.10-P-1001-01A Self-locking nut of flexible joint to transmission or front propeller shaft
M10 Nm 40
M12 Nm 60
n Power steering pump
Number Designation Model 209.316/ 361/365/ 375/376/ 461/465 475/476
BA46.30-P-1003-01D Banjo bolt of high pressure flexible hose to power steering pump
Nm 45
BA46.30-P-1004-01D Return line to power steering pump Nm 2
n Exhaust system
Number Designation Engine 112, 113.968 in model 209
Engine 113.987 in model 209
BA49.10-P-1007-01A Bolt of exhaust bracket to transmission Nm 20 20
BA49.10-P-1008-01A Self-locking nut to front exhaust pipe Nm 20 20
n Refrigerant compressor
Number Designation Engine 113.968
Engines 113.987/988/989/ 990/991
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 6
BA83.55-P-1001-01A Bolt, refrigerant compressor to bracket Nm 20 20
j Engine lubrication
Number Designation Engine 113.963/ 963/965
Engine 113.987/988/ 990/992/993
BF18.00-P-1001-01H Engine oil Filling capacity with oil filter Liters 7.5 8,5
Filling capacity without oil filter Liters 7.0 8,0
Specifications for Operating Fluids
Sheet BB00.40-P-0229-01A BB00.40-P-0229-01A
Sheet BB00.40-P-0229-03A BB00.40-P-0229-03A
Sheet BB00.40-P-0229-05A BB00.40-P-0229-05A
119 589 04 63 00
Set of plugsPressure hoseHand pump
210 589 00 71 00129 589 00 91 00
Commercially available tools (see Workshop Equipment Manual)
Number Designation Make (e. g.) Order number WH58.30-Z-1001-07A Engine hoist (self-locking), load capacity 500 kg, chain length 1.3 m (recommended for cars and cross-country vehicles) Bäcker Herderstrasse
D-42853 Remscheid
3188
Workshop equipment/MB testers (see Workshop Equipment Manual)
WE58.40-Z-1013-06A STAR DIAGNOSIS Compact diagnosis system for passenger cars, order number 6511 1801 00
Auxiliary repair materials
Number Designation Order number BR00.45-Z-1003-06A Liquid lubricant (Naphtolen H) 000 989 01 60
Copyright DaimlerChrysler AG 17.10.2015 CD-Ausgabe G/07/05 . This WIS print-out will not be recorded by Modification services.Page 7

 

easy 30 minute job, requiring only basic set of tools

 

Going by Dmtypr's posting history the next thread will be: "Need help smelting iron ore [urgent!]" lol

 

Nice write up there PJG even if it be from the WIS. Dibs to you for putting it up man.

 

This is awesome. I'm currently cleaning/organizing my entire second garage (where the all mighty clk is....) putting all my tools in order and finding space to temporarily place all of the "nooks and crannies..."

Also I have an update on the car restore:

Recently bought rear passenger side quarter panel and front cross member for just $800.0
in the process of removing inner panels and rear seats to re-solder. Also removing the a-c pillars thinking on doing alcantra on them still not sure..

Thanks for your replies guys

 

Post pics of the tear down if you could please. Many of us don't get to see the car torn apart.

 

Will do.