The operation "Engine, Remove and Install" is described for an Y 22 DTH engine with manual transmission and LHD. Proceed analogously for other engine and equipment versions.
Cable ties which are released or severed for removal of the engine must be re-installed in the same position during installation.
Turn steering wheel to straight-ahead position, remove ignition key and allow steering lock to engage.
Remove
In vehicles with AC: Drain AC – see operation "AC, Drain" in group "D".
Remove lower engine compartment cover (1).
Open coolant drain bolt (2) on radiator – collect escaping coolant.
Remove complete exhaust system.
Remove propshaft – see operation " Propshaft, Remove and Install or Replace" in group "F".
Remove engine cover (6) from cylinder head cover.
Unclip coolant hose (1) from air intake hose and disconnect wiring harness plug (3) from hot film mass air flowmeter.
Detach engine vent hose (2) from cylinder head cover.
Remove air intake hose (7) from turbocharger and upper part of air cleaner housing.
Remove charge air hoses (4) and (5).
Release lower coolant hose (1) in direction of arrow and remove from heater core – unclip coolant hose from bracket and lay aside.
Detach coolant hose (2) from cylinder head.
Remove coolant hoses (3) and (4) from thermostat housing.
Detach coolant hose (5) from alternator bracket (coolant flange).
For vehicles with air conditioning: Remove refrigerant lines – see operation "Pipes and Hoses, Remove and Install" in group "D".
Remove fastening bolts (1) and (2) from positive terminal.
Remove fastening bolt (3) from ground terminal.
Disconnect multiple plug (4) (rotary catch).
Detach all necessary cable ties and lay starter wiring harness aside on engine.
Remove relay frame cover (9).
Remove engine control unit (8) from relay frame. Release wiring harness plug (4) in direction of arrow and detach from engine control unit.
Disconnect wiring harness plug (6) from pre-heater system control unit.
Remove relay (7) with socket from relay frame.
Disconnect multiple plug (2) (rotary lock).
Remove fuse carrier cover (10).
Remove fuse with socket (3) from fuse carrier.
Remove wiring harness plug (1) from exhaust gas recirculation solenoid valve.
Remove engine wiring harness with rubber grommet (5) from relay frame and lay aside on engine – detach all necessary cable ties.
Remove brake servo vacuum line (1) from vacuum pump – press in lug (arrow) and disconnect brake servo vacuum line.
Disconnect vacuum line (2) from exhaust gas recirculation solenoid valve.
Disconnect vacuum line (3) from exhaust gas recirculation valve.
Remove vacuum line (7) from T-piece.
Remove oil leak line (6) from fuel return line connection.
Remove fuel feed line (4) and fuel return line (5) from injection pump – collect fuel.
Unclip fuel lines from cylinder head cover and lay aside.
Drain power steering fluid reservoir (5) with suitable suction device.
Detach hydraulic lines (3) and (4) from power steering pump – collect escaping hydraulic fluid.
Detach vacuum hose (2) from vacuum unit for turbocharger adjuster (1).
Top up brake fluid reservoir completely and close off with dummy plug.
Open retaining strap (2) for connecting piece on bulkhead.
Detach retaining clip (1) and disconnect clutch actuation pressure line. Reinsert retaining clip.
Front Wheels, Remove.
Detach fastening nuts from tie rods and press left and right tie rods out of steering knuckle with KM-507-C (1).
Release idler bracket fastening bolts (2) – do not remove yet.
Remove cover cap from fastening nut on steering arm.
Remove fastening nut on steering arm (1).
Press out steering arm (2) with KM-146-01.
Remove fastening nuts (4) from idler bracket (3) and remove entire steering linkage.
Detach fastening nuts for link rod (1) on both sides from stabiliser – counterhold with open-ended spanner at the flattened surfaces.
For vehicles with xenon headlamp:
Disconnect vehicle level control sensor wiring harness (2). Remove ball head (3) from vehicle level control sensor.
Detach fastening nuts (1) and remove fastening bolts.
Pull guide joints (2) downwards out of steering knuckle.
Remove 4 shift outrigger cover clips (arrows).
Push cover forwards.
Detach retainer (arrow) from pin.
Pull pin out from shift rod and fork.
Remove fastening bolts (arrows) from shift outrigger.
Disconnect AC compressor wiring harness plug (1).
Note. Before positioning the Centring Mount KM-6190, the split pins of the centring pins (1) and (3) must be pulled out so that the centring pins cannot engage the corresponding mounts.
Remove
Install Base Frame KM-904 with Centring Mount KM-6190 on hydraulic jack and position without play under front axle body – ensure that the centring pins (2) and (4) sit in the corresponding mounts (use hydraulic jack which can be lowered at least 100 cm).
Important: Removal of the front axle body with an impulse or impact screwdriver is not permissible. Note various lengths of bolts.
Remove
Unscrew transmission holder from underbody.
Remove front fastening bolts (1), centre fastening bolts (2) and rear fastening bolts (3).
Carefully lower front axle body with engine and transmission.
Important: Ensure the threads of the captive nuts move freely before installing front axle body with engine and transmission, replace captive nuts if necessary.
Note. Before installing the engine, the centring pins (1) and (3) must be pushed up and secured with the corresponding split pins.
Install
Carefully move drive unit into engine compartment until centring pins (1) and (3) engage in the appropriate mounts of the underbody – ensure that no attaching parts are damaged.
Install
Insert new fastening bolts for front axle body to front member and side member.
Tighten fastening bolts (1) for front of front axle body to front member – tightening torque 65 Nm / 48 lbf. ft. + 30° + 15°.
Tighten fastening bolts (2) for centre of front axle body to side member – tightening torque 150 Nm / 111 lbf. ft. + 30° + 15°.
Tighten fastening bolts (3) for rear of front axle body to side member – tightening torque 130 Nm / 96 lbf. ft. + 30° + 15°.
Attach transmission holder to underbody – tightening torque 45 Nm / 33 lbf. ft. 1) .
Remove
Lower hydraulic jack and detach Base Frame KM-904 and Centring Mount KM-6190 from hydraulic jack.
Install
Connect wiring harness plug to AC compressor.
Attach shift outrigger to transmission – tightening torque 20 Nm / 15 lbf. ft.
Attach shift outrigger to shift lever and attach cover.
Connect guide joints to steering knuckle – tightening torque 100 Nm / 74 lbf. ft.
For vehicles with xenon low beam headlamps: Attach ball head and wiring harness plug to vehicle level control sensor.
Attach link rods to stabiliser – tightening torque 65 Nm / 48 lbf. ft.
Attach idler bracket to body – tightening torque 55 Nm / 41 lbf. ft. + 75° + 15° 2) .
Attach steering arm to steering shaft with new fastening nut – tightening torque 160 Nm / 118 lbf. ft.
Attach cover cap to steering arm fastening nut.
Connect left and right tie rods to steering knuckle with new fastening nuts – tightening torque 60 Nm / 44 lbf. ft.
Attach front wheels – tightening torque 110 Nm / 81 lbf. ft.
Connect clutch actuation pressure line and fasten retaining band.
Attach vacuum hose to vacuum unit for turbocharger adjuster.
Attach hydraulic lines with new gaskets to power steering pump – tightening torque 37.5 Nm / 27.5 lbf. ft.
Attach fuel lines with new gaskets to injection pump – note different diameters of banjo bolts and gaskets – tightening torque 15 Nm / 11 lbf. ft.
Attach oil leak line to fuel return line connection – ensure correct seating.
Attach vacuum lines to T-piece, exhaust gas recirculation valve and exhaust gas recirculation solenoid valve.
Attach brake servo vacuum line to vacuum pump – quick fitting must audibly engage.
Insert engine wiring harness with rubber grommet into relay frame – ensure correct routing of wiring harness.
Attach wiring harness plug to exhaust gas recirculation solenoid valve – ensure correct routing of cable.
Insert fuse with socket into fuse carrier and attach fuse carrier cover.
Attach multiplug (twist lock).
Insert relay with socket into relay frame.
Attach wiring harness plug to pre-heater system control unit.
Attach wiring harness plug to engine control unit and push engine control unit into relay frame.
Install relay frame cover.
Route starter wiring harness.
Attach multiplug (twist lock).
Attach cable connections to ground terminal and positive terminal – ensure correct routing of cables.
For vehicles with air conditioning: Install refrigerant lines – see operation "Pipes and Hoses, Remove and Install" in group "D".
Attach coolant hose to alternator bracket (coolant flange).
Attach coolant hoses to thermostat housing and cylinder head – x3.
Remove lower coolant hose at heater core – ensure correct routing and seating.
Attach both charge air hoses – tightening torque – 3.5 Nm / 2.6 lbf. ft.
Attach air intake hose to turbocharger and air cleaner housing – tightening torque 3.5 Nm / 2.6 lbf. ft.
Attach engine vent hose to cylinder head cover.
Attach wiring harness plug to hot film mass air flowmeter and clip coolant hose into air intake hose.
Install engine cover on cylinder head cover.
Install propshaft – see operation " Propshaft, Remove and Install or Replace" in group "F".
Install exhaust gas system completely.
Close coolant drain bolt on radiator.
Bleed hydraulic clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed " in group "K".
Top up power steering fluid reservoir – see operation "Hydraulic System, Charge" in group "M".
Vehicles with air conditioning: Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D".
Bleed fuel system – see operation "Fuel System, Bleed (X 20 DTH, Y 22 DTH)" in group "L".
Attach lower engine compartment cover - tightening torque 5 Nm / 3.7 lbf. ft.
Inspect
Top up cooling system – see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".
1
) Clean thread and insert with bolt locking compound (red).
2
) Use new bolts.