Caution
For vehicles with airbag: Turn steering to straight ahead position, remove ignition key and engage steering lock.
Remove
Remove clamping bolt on steering column intermediate shaft (interior).
In version with AC: drain air conditioning system - see operation "Draining air conditioning system" in group "D".
Open coolant drain bolt – collect escaping coolant.
Disconnect ground cables (3) and (4) from ground connection and disconnect ground connection (5) from battery.
Disconnect positive lead (1) from positive terminal and disconnect positive terminal (2) from battery.
Remove battery.
Detach battery support (6) and pre-heating system control unit bracket (7) from body – remove battery support.
Detach and remove charge air pipe (2) from turbocharger and intercooler.
Detach and remove charge air hose (1) from intake manifold and intercooler.
Detach coolant hose (3) from coolant line and set aside.
Detach coolant hose (1) from coolant compensation tank.
Detach coolant hose (2) from radiator.
Detach and remove lower radiator hose (2) from radiator and coolant pipe.
Release coolant hose (1) in direction of arrow and detach from heater core.
Unclip brake servo vacuum line (3) from vacuum pump.
Detach or separate wiring harness plugs from coolant temperature sensor (4), hot film mass air flow meter (5), charge pressure sensor (1) and from exhaust gas recirculation solenoid valve (2).
Remove wiring trough (3) from camshaft housing and set aside with wiring harness.
Release wiring harness plug (1) in direction of arrow and detach from fuel injection pump control unit.
Remove cable connections (2) from sheathed glow plugs.
Disconnect wiring harness plug (3) from oil temperature sensor.
Disconnect wiring harness plug (6) from crankshaft pulse pick-up and set aside.
Detach wiring harness plug (4) from reversing lamp switch.
Unclip wiring trough (5) from both brackets and set aside with wiring harness.
Detach multiplug (1) (turn lock).
Remove fuse box cover (2).
Disconnect wiring harness plug (5). Detach ground cable (4) from body. Unclip fuse carrier (3) with fuse from fuse box - uncover steering wiring harness and put aside with transmission.
Detach pressure line (6) with connector from pressure line for central release mechanism on clutch housing – for this purpose, unlock clamp with screwdriver detach clutch pressure line – then bend clamp slightly together and re-insert in connection piece – note installation position of clamp!
Detach fuel feed line from fuel filter housing and fuel return line at opposite separation point.
Remove air cleaner housing with air intake hose and hot film mass air flow meter – see illustration "Air Ducts".
Front Wheels, Remove.
Remove front panelling – see operation "Front Panelling, Remove and Install" in group "A".
Detach swing arm (1) on both sides from spring strut support tube – counterhold with open-ended spanner at the two flattened surfaces.
Withdraw axle shafts on both sides from wheel hub (do not remove from transmission) see operation "Axle Shafts, Remove and Install" in group "E".
For version with air conditioning:
Remove fastening bolt (1) and disconnect refrigerant line.
Remove fastening bolt (2) and detach refrigerant line from receiver-dryer.
Unlock wiring harness plug (1) in direction of arrow and detach from cooling module control unit.
Disconnect ground cable (2) from body.
Remove front exhaust pipe - see operation " Removing and installing intermediate muffler and front exhaust pipe" in group "L".
Release clamp (1) from shift rod and disconnect shift guide from shift rod.
Note. The drive unit must be aligned to the front axle body using KM-6173 and KM-6001-A in order to ensure correct alignment of the drive unit after releasing the fastening bolts for the right and left engine damping blocks. The attachment of KM-6173 and KM-6001-A is described in the following.
Remove
Attach KM-6173 (3) to front axle body – screw up support bearing (2) until pin is seated flush in mount (1) on cylinder block.
Release fastening bolts (arrows) for adjustment rails on KM-6001-A (1).
Insert KM-6001-A as illustrated – pins (2) and (5) must sit in guide holes of front axle body.
Tighten fastening bolts for adjustment rails.
Screw up front support bearing (4) and rear support bearing (3) until contact is made with guide pins of front engine damping block and rear engine damping block bracket – the guide pins must seat free from play in the support bearings.
Detach engine damping block bracket on the right (1) and left (2) from engine damping block support.
Install
Install Base Frame KM-904 with Centring Mount KM-6000 on hydraulic jack and position free of play under front axle body (use hydraulic jack which can be lowered at least 100 cm).
Caution
Dismantling of front axle body using an impulse or impact screwdriver is not permissible. Note dissimilar bolt lengths.
Note. For greater clarity, illustration G 3441 shows the front axle body without hydraulic jack and centring mount.
Remove
Dismantle six rear fastening nuts (4) and remove triangular plates. Remove right (1) and left (3) front bolts. Remove centre fastening bolts (2).
Carefully lower front axle body – thereby ensuring that no attaching parts are damaged. Note steering wiring harness!
Caution
Ensure the threads of the captive nuts move freely before installing front axle body with drive unit, steering gear and radiator, replace captive nuts if necessary.
Install
Carefully guide front axle body with entire drive unit, steering gear and radiator into engine compartment and position free of play on chassis – thereby ensuring that no attaching parts are damaged.
Attach front axle body to vehicle underbody using new fastening bolts (1 - 4) - tightening torque 90 Nm + 45° + 15°.
Caution
Installing the front axle body using an impulse or impact screwdriver is not permissible. Note dissimilar bolt lengths and washers.
Install
Attach left and right engine damping block bracket to auxiliary engine damping block support – 55 Nm / 41 lbf. ft.
Remove
Remove Mount KM-6001-A and Engine Mount KM-6173.
Install
Push shift guide onto shift rod.
Install front exhaust pipe - see operation "Removing and installing intermediate muffler and front exhaust pipe" in group "L".
Connect ground lead to body. Attach wiring harness plug to cooling module control unit and lock.
For version with air conditioning:
Attach refrigerant line to receiver-dryer - tightening torque 20 Nm.
Attach refrigerant line (compressor) to refrigerant line (engine compartment/body) – tightening torque 20 Nm / 15 lbf. ft.
Install axle shafts – see operation "Axle Shafts, Remove and Install" in group "E".
Attach swing arms on both sides to spring strut support tube with new fastening nuts – counterhold with open-ended spanner at two flattened surfaces – tightening torque 65 Nm / 48 lbf. ft.
Install front panelling – see operation "Front Panelling, Remove and Install" in group "A".
Attach front wheels – tightening torque – 110 Nm / 81 lbf. ft.
Install air cleaner housing with air intake hose and hot film mass air flow meter – see illustration "Air Ducts".
Attach or connect together fuel feed and return lines.
Attach pressure connection for hydraulic clutch actuator to manual transmission.
Route and connect steering wiring harness.
Connect multiplug (twist connection).
Attach both cable troughs to engine and attach or connect together wiring harness plugs – note cable routing.
Clip brake servo vacuum line to vacuum pump.
Attach all coolant hoses – ensure correct seating.
Attach charge air hose to upper part of intake manifold and intercooler – tightening torque 3.5 Nm / 2.6 lbf. ft.
Attach charge air pipe to turbocharger and charge air cooler - tightening torque 3.5 Nm.
Attach battery support to body.
Attach pre-heater relay control unit bracket to body.
Install battery on battery support.
Attach cable connections to battery.
Coat new clamp bolt with screw locking compound (red) and attach steering column intermediate shaft to steering gear – tightening torque 22 Nm / 16.2 lbf. ft.
Bleed hydraulic clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed (F13/F17/F18/F23)" in group "K".
Adjust transmission shift linkage – see operation "Transmission Shift Linkage, Adjust (F13/F17/F18)" in group "K".
In version with AC: Fill air conditioning system - see operation " Evacuating and filling air conditioning system" in group "D".
Inspect
Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".