Caution
Fuel escapes – observe safety measures and national legislation. The fuel system is under pressure. Remove fuel pump relay – see operation "Fuel Pump Relay, Remove and Install". Start engine for at least 5 sec. to reduce fuel pressure.
For Z 16 SE engine: Reduce fuel pressure using Fuel Pressure Gauge KM-J-34730-91 from test connection. Collect escaping fuel in a suitable container.
Note. The "Engine, Remove and Install" operation is described for an X 16 SZR engine with air conditioning and RHD. Proceed analogously for other equipment versions.
Cable ties detached for removal of the engine must be reattached at the same location on installation.
Caution
Turn steering wheel to straight-ahead position, remove ignition key and allow steering lock to engage.
Remove
Remove clamping bolt (1) on steering column intermediate spindle (interior).
Version with AC: Drain AC – see operation "Air Conditioning, Drain" in group "D".
Detach ground cable (3) from ground terminal (4) and ground terminal from battery.
Detach positive cable (2) from positive terminal (1) and positive terminal from battery.
Remove battery.
Detach battery support (5) from body and remove.
Open coolant drain bolt – collect escaping coolant.
Remove air cleaner housing with air intake cover – see illustration "Air Ducts (X 16 SZR)".
For Z 16 SE engine: Remove air cleaner housing with air intake hose – see illustration "Air Cleaner Housing (Z 16 SE)".
Remove pre-heating hose from heat shield and resonator.
Note. When detaching the tank vent valve hose, ensure that the valve connection is not damaged. Damaged valves must be replaced.
Caution
Damaged valve supports can cause a vehicle fire as a result of leaks.
Remove
Detach wiring harness plug (1) and tank vent valve hose (2) from tank vent valve.
For Z 16 SE engine: Detach lines and wiring harness plugs from intake manifold – see operation "Intake Manifold, Remove and Install (Z 16 SE)".
Detach and set aside accelerator actuation cable (4).
Detach fuel lines (2) from throttle body – collect escaping fuel in suitable container.
Disconnect vacuum hose intake manifold pressure sensor (5) from throttle valve injection housing.
Detach brake servo vacuum line (3) from intake manifold.
Disconnect wiring harness plug (1) from intake manifold pressure sensor.
Detach multiplug (1) (turn lock).
Detach multiplug (2) (grey).
Remove cable trough (4) from body (arrow).
Detach engine control unit cover and disconnect wiring harness plug (3) from engine control unit – lay aside wiring trough.
For Z 16 SE engine: Release wiring harness plug (1) in direction of arrow and detach from engine control unit. Unclip wiring harness from bracket and lay aside.
For models with automatic transmission: Disconnect or remove transmission wiring harness plug and expose wiring harnesses.
Withdraw fuse carrier (1) from bracket, remove ground cable (2) from body and disconnect wiring harness plug (3) – place steering cable bunch out of way.
Release coolant hoses (4) in direction of arrow and disconnect from heater core.
Detach coolant hose from coolant compensation tank.
Remove coolant hose to coolant compensation tank from radiator.
For version with manual transmission:
Detach delivery line with connector (1) from central equipment delivery line at clutch housing – to do this, release clamp (2) with screwdriver and remove; then bend clamp together slightly and re-insert in connector.
For version with automatic transmission:
Press selector lever actuation cable (3) from actuation lever. Lever off retaining clip (4) with screwdriver and unclip selector lever actuation cable out of counterhold.
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 op-ended spanner at the two flattened surfaces.
Withdraw axle shafts on both sides from wheel hub (do not remove from transmission) – see operation "Axle Shaft, Remove and Install" in group "E".
Remove lower engine splash guard.
Unlock wiring harness plug (2) in direction of arrow and detach from cooling module control unit.
Disconnect ground cable (3) from body.
Remove front exhaust pipe with catalytic converter and centre muffler – see operation "Centre Muffler and Front Exhaust Pipe, Remove and Install" in group "L".
For version with manual transmission: Release clamp (1) from shift rod and remove 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.
Install
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.
Remove
For version with air conditioning:
Remove fastening bolt (1) and disconnect refrigerant line.
Remove fastening bolt (2) and detach refrigerant line from receiver-dryer.
Detach right engine damping block bracket (1) and left engine damping block bracket (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, the illustration shows the front axle body without hydraulic jack and centring mount.
Remove
Remove six rear fastening bolts (4) on left and right. Remove front fastening bolts on right (1) and left (3). Remove centre fastening bolts (2).
Carefully lower front axle body with entire drive unit, steering gear and radiator – thereby ensuring that no attaching parts are damaged.
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 with new fastening bolts (1- 4) – tightening torque 90 Nm / 66.5 lbf. ft. + 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 right engine damping block bracket to engine damping block support – tightening torque 55 Nm / 41 lbf. ft.
Attach left engine damping block bracket to engine damping block support – tightening torque 55 Nm / 41 lbf. ft.
For version with air conditioning:
Connect refrigerant line – tightening torque 20 Nm / 15 lbf. ft.
Attach refrigerant line to receiver-dryer – tightening torque 20 Nm / 15 lbf. ft.
Remove
Remove Mount KM-6001-A and Engine Mount KM-6173.
Install
For version with manual transmission: Attach shift guide using clamp to shift rod – it is only tightened after the transmission shift linkage is adjusted.
For version with automatic transmission: Clip selector lever actuator cable in counterpart and slide in retaining clamp. Attach selector lever actuator cable to actuator lever for selection lever.
Install front exhaust pipe with catalytic converter and centre muffler – see operation "Centre Muffler and Front Exhaust Pipe, Remove and Install" in group "L".
For version with hex bolts: Install front exhaust pipe to exhaust manifold with new gasket – tightening torque 35 Nm / 26 lbf. ft. 1) .
For version with hex nuts: Attach front exhaust pipe to exhaust manifold with new gasket – tightening torque 45 Nm / 33.5 lbf. ft. 2) .
Install lower engine splash guard.
Attach wiring harness plug to cooling module control unit and connect ground lead to body.
Install axle shafts – see operation "Axle Shaft, Remove and Install" in group "E".
Attach swing arms on both sides to spring strut support tube with new fastening nuts – counterhold with op-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.
Close coolant drain bolt.
For version with manual transmission: Attach pressure connection for hydraulic clutch actuator to manual transmission.
Attach coolant hoses – ensure correct seating.
Route steering wiring harness, clip fuse carrier into bracket, connect wiring harness plug and ground cable to body.
For version with automatic transmission – connect transmission wiring harness plug.
Attach cable trough to body and wiring harness plug to engine control unit.
Install engine control unit cover.
Connect multiplug (turn lock) and multiplug (grey).
Connect wiring harness plug to intake manifold pressure sensor.
Attach brake servo vacuum line to intake manifold.
Attach intake manifold pressure sensor vacuum hose to throttle valve injection housing.
Attach fuel lines to throttle valve guards – tightening torque 15 Nm / 11 lbf. ft.
Attach accelerator actuation cable.
For Z 16 SE engine: Attach hoses and wiring harness plugs to intake manifold – see operation "Intake Manifold, Remove and Install (Z 16 SE)".
Connect wiring harness plug and tank vent valve hose to tank vent valve.
Attach pre-heating hose to heat shield and resonator.
Install air cleaner housing with air intake cover – see illustration "Air Ducts (X 16 SZR)".
For Z 16 SE engine: Install air cleaner housing with air intake hose – see illustration "Air Cleaner Housing (Z 16 SE)".
Attach battery support to body- tightening torque 15 Nm / 11 lbf. ft.
Install battery.
Attach positive terminal to battery and positive lead to positive terminal.
Attach ground terminal to battery and ground lead to ground terminal.
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.
Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D".
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".
Inspect
Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".
1
) Insert bolts with assembly paste (white).
2
) Use new nut(s).