Removal and Replacement

Removing, Installing Electric Fan

Part 1:

Part 2:

Model 203 with 4MATIC:

DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking.
- Wear acid protection gloves, clothes and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

CAUTION: Model 209: Do not connect quiescent current retention unit, otherwise damage may occur to control module.



2 Remove engine suction fan ducts (1) in front of air cleaner (2)
3 Unscrew bracket of oil line rack-and-pinion steering (20) at front end
- Model 203 with 4MATIC

4 Unscrew bracket of oil line level control (21) at timing case
- Model 203 with 4MATIC and level control

5 Disconnect connector (3) of the electric suction fan engine and AC with integrated control (M4/7)
6 Remove horn (4)

NOTE: Unplug contact of audible warning device.

7 Unscrew bolts of steering oil cooler at front end crossmember.

NOTE: Unscrew two screws

8 Detach hydraulic line of power steering (5) at front end crossmember (7)
9 Take off front end crossmember (7) at front crossmember.

NOTE: Unscrew bolts (8).

10 Unscrew bolts (10) at front end crossmember (7) on right and left.
11 Detach hood cable (11)
12 Remove retaining clips (12) of air dueling

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 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.

13 Drain coolant


14 Press coolant line (13) out of fixture
15 Remove cable straps at front end crossmember (7)
16 Separate plug connection of hood lock on right (15)

17 Remove lock carrier (7) together with hood cables

NOTE: If the rubber mounts (19) are stuck in the radiator, do not pull front end crossmember up with force, but unscrew retaining pin (9) on right and left. Press together retaining clamp (14) of radiator on right and left and unhook front end crossmember (7) and remove.

18 Detach top coolant line at radiator
- Model 209.375/376 with Engine 113.968/987. Use a screwdriver to push back damp until it locks in place.

NOTE: Installation: Replace O-ring of coolant line.

19 Press the clamps (16) on right and left and at the same time pull electric suction fan engine and AC with integrated control (M4/7) upwards

20 Take out electric suction fan engine and AC with integrated control (M4/7) upwards.

NOTE: Installation: Ensure that the plates (17) of the electric suction fan engine and AC with integrated control (M4/7) are located in the mounts (18) of the radiator on right and left

21 Install in the reverse order
22 Carry out operational check of hood lock
23 Inspect gaps of hood
24 Perform basic programming
25 Read out fault memory with STAR DIAGNOSIS and erase if necessary.