AR20.00-P-1142M
Drain, pour in coolant
8.11.99
ENGINE
612.963 in MODEL 163.113
P20.20-2083-12
1
Front noise encapsulation bottom part
2
Radiator
3
Radiator drain tap
4
Siphon hose
Draining
Danger!
Risk of injury
to
fingers being jammed or
pinched
when removing, installing or aligning
hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
AS00.00-Z-0011-01A
Danger!
Risk of injury
to skin and eyes suffering
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
1
Open engine hood and raise to vertical position
Have assistant secure hood.
AR88.40-P-1000GI
2
Open cap of coolant expansion reservoir
Turn cap half a turn in the anti-clockwise
direction, release pressure, and then unscrew
cap.
3
Remove front noise encapsulation bottom
part (1)
4
Attach siphon hose (4) to drain connection of
radiator
5
Drain coolant at radiator (2) on right
To do this, turn drain tap (3) at radiator (2)
into position "1" (arrow).
Disposal of coolants.
Pay attention to legal provisions or local
wastewater regulations!
Refer to Environmental Protection Catalog
issued by MBVD/PWU for locations in
Germany.
6
Clean cooling and heating system
Clean cooling and heating system in case
of impurities. See
#
Remove oil from cooling and heating system.
AR20.00-P-1250B
Pour in
Notes on coolant
All engines
AH20.00-N-2080-01A
7
Turn drain tap (3) at radiator (2) into position
"0" (arrow)
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1
Danger!
Risk of accident
caused by vehicle starting
off by itself when engine is running.
Risk of
injury
caused by contusions and burns when
working in engine during starting procedure
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
8
Pour in coolant
Warm up engine by running at moderate
revs. Top up coolant constantly at coolant
expansion reservoir. Close coolant expansion
tank once
coolant temperature is 60-70 °C.
*BF20.00-P-1001-02E
Note on coolant level
Model 124, 129, 140, 163.113, 168, 170, 202,
208, 210, 220, 463
AH20.00-P-1142-01A
9
Inspect cooling system for leaks
AR20.00-P-1010HA
Cooling system
Number
Designation
Engine
612.963
BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0
Filling capacity of anticorrosion/
antifreeze agent down to
-37 °C
Liter
Y
5.5
Filling capacity of anticorrosion/
antifreeze up to -45 °C
Liter
Y
6.25
Specifications for Operating
Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2
AR20.00-P-1142HA
Draining and pouring in coolant
2.4.93
ENGINE
112 in MODELS 129, 163, 202, 208, 210, 211.061 /065 /261 /265 /080 /280 /082 /282, 220, 230.467
ENGINE
113 in MODELS 129, 163, 202, 208, 210, 211.070 /083 /283, 215, 220
ENGINE
113.962 in MODELS 463.206 /240 /241 /247 /248 /249 /254
ENGINE
112.945 in MODELS 463.209 /232 /233 /244 /245 /250
ENGINE
137 in MODELS 215, 220
ENGINE
113.982 in MODELS 463.241 /243 /246
P20.00-0215-06
Illustrated on model 202
1
Coolant expansion reservoir
2
Cooling system cap
3
Radiator drain plug
3a
Drain hose (inner diameter 12 mm)
4
Crankcase drain plug
4a
Drain hose (inner diameter 14 mm)
P20.00-2045-06
Shown on model 215 with M137
1
coolant expansion reservoir
2
Cooling system cap
3
Radiator drain plug
3a
Drain hose (inner diameter 12 mm)
Draining
Danger!
Risk of injury
to skin and eyes suffering
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
Notes on coolant
All engines
AH20.00-N-2080-01A
Copyright DaimlerChrysler AG 12.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1
AR20.00-P-1142M
Drain, pour in coolant
8.11.99
ENGINE
612.963 in MODEL 163.113
P20.20-2083-12
1
Front noise encapsulation bottom part
2
Radiator
3
Radiator drain tap
4
Siphon hose
Draining
Danger!
Risk of injury
to
fingers being jammed or
pinched
when removing, installing or aligning
hoods, doors, trunk lid/tailgate or sliding roof.
When moving components, ensure that no
body parts or limbs are within the operating
range of moving parts.
AS00.00-Z-0011-01A
Danger!
Risk of injury
to skin and eyes suffering
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
1
Open engine hood and raise to vertical position
Have assistant secure hood.
AR88.40-P-1000GI
2
Open cap of coolant expansion reservoir
Turn cap half a turn in the anti-clockwise
direction, release pressure, and then unscrew
cap.
3
Remove front noise encapsulation bottom
part (1)
4
Attach siphon hose (4) to drain connection of
radiator
5
Drain coolant at radiator (2) on right
To do this, turn drain tap (3) at radiator (2)
into position "1" (arrow).
Disposal of coolants.
Pay attention to legal provisions or local
wastewater regulations!
Refer to Environmental Protection Catalog
issued by MBVD/PWU for locations in
Germany.
6
Clean cooling and heating system
Clean cooling and heating system in case
of impurities. See
#
Remove oil from cooling and heating system.
AR20.00-P-1250B
Pour in
Notes on coolant
All engines
AH20.00-N-2080-01A
7
Turn drain tap (3) at radiator (2) into position
"0" (arrow)
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 1
Danger!
Risk of accident
caused by vehicle starting
off by itself when engine is running.
Risk of
injury
caused by contusions and burns when
working in engine during starting procedure
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
8
Pour in coolant
Warm up engine by running at moderate
revs. Top up coolant constantly at coolant
expansion reservoir. Close coolant expansion
tank once
coolant temperature is 60-70 °C.
*BF20.00-P-1001-02E
Note on coolant level
Model 124, 129, 140, 163.113, 168, 170, 202,
208, 210, 220, 463
AH20.00-P-1142-01A
9
Inspect cooling system for leaks
AR20.00-P-1010HA
Cooling system
Number
Designation
Engine
612.963
BF20.00-P-1001-02E
Cooling system
Total capacity
Liter
Y
11.0
Filling capacity of anticorrosion/
antifreeze agent down to
-37 °C
Liter
Y
5.5
Filling capacity of anticorrosion/
antifreeze up to -45 °C
Liter
Y
6.25
Specifications for Operating
Fluids
SheetBB00.40-P-0310-01A
SheetBB00.40-P-0325-00A
Copyright DaimlerChrysler AG 28.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 2
P01.30-0299-06
20
Bolts cylinder head
!
timing case cover
21
Cylinder head bolts
22
Cylinder head left
23
Cylinder head right
24
Left cylinder head gasket
25
Right cylinder head gasket
26
Dowel sleeves
Remove/Install
Notes on self-locking nuts and bolts
All models
AH00.00-N-0001-01A
External torx set
*001589760900
Torx bit set
*000589011000
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
1
Disconnect battery ground cable
Installation:
After connecting, read out
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
AR54.10-P-0003A
Notes on battery
All models
AH54.10-P-0001-01A
Danger!
Risk of death
caused by vehicle slipping or
toppling off of the lifting platform.
Align vehicle between the columns of the
hydraulic hoist and position the four support
plates below the hoist support points specified
by the vehicle manufacturer.
AS00.00-Z-0010-01A
2
Place the vehicle on lifting platform
AR00.60-P-1000GH
3.1
Remove air guide (1)
Only with engine 113.942
Danger!
Risk of injury
to skin and eyes suffering
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
4
Drain coolant
Remove coolant hose at bottom on
radiator.
AR20.00-P-1142HA
5
Remove engine cover
6.1
Remove viscous fan (2)
All except model 163.174 /175 with
engine 113.981 /965.
Right-hand thread!
AR20.40-P-5660C
7.1
Remove the fan shroud (3).
Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2
Remove electric fan
Only model 163.174/ 175.
AR20.40-P-5000GH
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
P01.30-0299-06
20
Bolts cylinder head
!
timing case cover
21
Cylinder head bolts
22
Cylinder head left
23
Cylinder head right
24
Left cylinder head gasket
25
Right cylinder head gasket
26
Dowel sleeves
Remove/Install
Notes on self-locking nuts and bolts
All models
AH00.00-N-0001-01A
External torx set
*001589760900
Torx bit set
*000589011000
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
1
Disconnect battery ground cable
Installation:
After connecting, read out
fault memory, encode radio and normalize
power windows.
Vehicles with stationary heater: Set time on
timer for stationary heater
AR54.10-P-0003A
Notes on battery
All models
AH54.10-P-0001-01A
Danger!
Risk of death
caused by vehicle slipping or
toppling off of the lifting platform.
Align vehicle between the columns of the
hydraulic hoist and position the four support
plates below the hoist support points specified
by the vehicle manufacturer.
AS00.00-Z-0010-01A
2
Place the vehicle on lifting platform
AR00.60-P-1000GH
3.1
Remove air guide (1)
Only with engine 113.942
Danger!
Risk of injury
to skin and eyes suffering
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
4
Drain coolant
Remove coolant hose at bottom on
radiator.
AR20.00-P-1142HA
5
Remove engine cover
6.1
Remove viscous fan (2)
All except model 163.174 /175 with
engine 113.981 /965.
Right-hand thread!
AR20.40-P-5660C
7.1
Remove the fan shroud (3).
Only model 163.154 /157 /172. Unscrew
bolts (4) from bottom of fan shroud
7.2
Remove electric fan
Only model 163.174/ 175.
AR20.40-P-5000GH
Copyright DaimlerChrysler AG 20.05.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
d by Modification services.
Page 2
GF54.30-P-2002A
Display instruments, location / task / function
24.10.96
MODEL
129, 140 as of 1.6.96,
163, 168, 170,
202 as of 1.8.96,
208 up to 31.7.99,
210 as of 1.6.96 up to 30.6.99
Display
Type of data transmission
D
Outside temperature indicator (A1p4)
D
Fuel level gauge (A1p2)
D
Engine oil pressure gauge (A1p3), only
model 129 and model 140
D
Low windshield washer fluid level
indicator lamp (A1e13), model 163 as of
01.09.01
Direct lines
GF54.30-P-3004A
D
Total mileage odometer (A1h4)
D
Electronic speedometer (A1p8)
D
Tachometer (A1p5)
D
Coolant temperature gauge (A1p1)
D
Active service system (ASSYST)
D
Gear indicator (A1p12), only model 168
CAN data lines
GF54.30-P-3005A
D
Electronic clock
Internal
GF54.30-P-3011A
Copyright DaimlerChrysler AG 04.06.2006 CD-Ausgabe G/10/04 . This WIS print-out will not be recorde
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Page 1