The operation "Engine, Remove and Install" is described for a Y 26 SE engine with manual transmission and LHD. Proceed analogously for other engine and equipment versions.
Cable ties detached for removal of the engine must be reattached at the same location on installation.
Turn steering wheel to straight-ahead position, remove ignition key and allow steering lock to engage.
Remove
For version with air conditioning: drain air conditioning system - see operation "Air Conditioning, Drain" in group "D".
Remove radiator damper (3 parts).
Open fuse carrier (4), release and pull out upwards.
Detach ground cable (3) from ground terminal and ground cable from battery.
Detach positive cable (5) from positive terminal and positive terminal from battery.
Remove battery.
Disconnect multiplug (white) (1) (twist lock).
Disconnect multiplug (brown) (2) (twist lock).
In version with automatic transmission: disconnect multi-plug (blue, screw-type connector)
Open relay frame cover.
Remove ground cable (3) from engine control unit.
Release wiring harness (1) and detach from engine control unit – pull wiring harness out of bracket slightly and remove upwards.
Disconnect wiring harness plug (2).
Drain power steering oil reservoir using suitable suction device.
Remove pre-volume chamber – see operation "Pre-volume Chamber, Remove and Install".
Open coolant drain screw - collect coolant.
Install
Close coolant drain screw.
Remove
Detach upper coolant hose (5) from coolant compensation tank.
Unclip coolant hoses (3) and (4) from brackets.
Detach upper coolant hose (2) from radiator.
Detach lower coolant hose (1) from coolant pipe.
Remove coolant hoses from auxiliary coolant pump (heater).
Release lower coolant hose of coolant compensation tank (1) from coolant pipe (2).
Release coolant hose (3) and pull from heater.
Remove hoses (1) from engine vent adapter.
Important: Fuel escapes – observe safety measures and national legislation. Reduce fuel pressure with pressure tester KM-J-34730-91 via test connection - collect escaping fuel in suitable container.
Remove
Detach fuel lines (4) from fuel distributor pipe adapter.
Detach line from tank vent valve to activated carbon canister at specified separation point.
Detach vacuum line (1) from shut-off valve.
Disconnect refrigerant lines (2) and (3) at quick fittings with KM-917.
Remove vacuum line (2) from oil reservoir (1) and remove high-pressure line (3) from power steering pump.
Detach T-piece for intake plenum switchover valve solenoid (2) from brake servo vacuum line.
Disconnect vacuum line (1) from T-piece.
Detach brake servo vacuum line (3) from intake plenum.
Top up brake fluid reservoir completely and close off with dummy plug.
Open retaining strap (2) for connecting piece on bulkhead.
Remove retaining clamp (1) and disconnect clutch operation pressure line - reattach retaining clamp.
Remove front wheels.
Remove lower engine compartment cover.
For vehicles with xenon headlamp:
Disconnect vehicle level control sensor wiring harness (2). Remove ball head (3) from vehicle level control sensor.
Remove link rod fastening bolts (1) from stabiliser - counterhold at flattened areas using open-ended spanner.
Detach fastening nuts (1) and remove fastening bolts.
Do not pull swivel joints (2) out of steering knuckle yet.
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 covering cap of steering arm fastening nut.
Remove fastening nut on steering arm (1).
Mark installation position of steering arm (2).
Push out steering arm with KM-146-01.
Remove entire steering linkage.
For version with automatic transmission:
Detach transmission fluid lines (1) and short-circuit - place collecting basin beneath.
Remove propeller shaft fastening bolts (2).
For version with automatic transmission:
Remove retaining clamp (1).
Detach selector lever linkage.
Remove 4 shift outrigger cover clips (arrows).
Push cover forwards.
Pull retaining plate (arrow) from bolt.
Pull pin out from shift rod and fork.
Remove fastening bolts (arrows) from shift outrigger.
Attach drive shaft to shift outrigger using cable ties.
Disconnect AC compressor wiring harness plug (1).
Detach exhaust system (1).
Remove transmission holder fastening bolts (2) from underfloor.
Install
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 to at least 100 cm).
The front axle body must not be dismantled using a pulse or impact screwdriver.
Pay attention to differing screw lengths.
Important: Before removing the engine, the split pins of the centring pins (1) and (3) must be pulled out so that the centring pins cannot engage in the corresponding mounts.
Remove
Remove front fastening bolts (1), centre fastening bolts (2) and rear fastening bolts (3).
Carefully lower front axle body with engine and transmission.
Note. Pay attention to swivel joints.
Lower hydraulic jack completely.
Important
Ensure the threads of the captive nuts move freely before installing front axle body 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.
Important: When moving in the engine, ensure that centring pins (1), (2), (3) and (4) engage in the corresponding mounts of the front axle body / underbody.
Install
Carefully insert front axle body with engine and transmission into engine compartment.
Note. Pay attention to swivel joints when inserting engine.
Place drive unit onto chassis without play - ensure that no attached parts are damaged.
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 / 33.2 lbf. ft. 1) .
Attach exhaust system.
Attach A/C compressor wiring harness plug.
Detach drive shaft from shift outrigger.
Attach shift outrigger to transmission – tightening torque 20 Nm / 15 lbf. ft.
Assemble shift rod and fork with bolt.
Place retaining plate onto bolt.
Attach shift outrigger cover.
In version with automatic transmission: attach shift lever linkage.
Attach propeller shaft - tightening torque 95 Nm / 70.1 lbf. ft.
For version with automatic transmission: Connect hoses of transmission fluid lines.
Attach idler bracket to body – tightening torque 55 Nm / 41 lbf. ft. + 75° + 15° 2) .
Attach link rods to stabiliser – tightening torque 65 Nm / 48 lbf. ft.
Attach steering arm to steering shaft with new fastening nut - pay attention to mark - tightening torque 160 Nm / 118 lbf. ft.
Place covering cap on steering arm fastening nut.
Connect guide joints to steering knuckle – tightening torque 100 Nm / 74 lbf. ft.
Connect left and right tie rods to steering knuckle with new fastening nuts – tightening torque 60 Nm / 44 lbf. ft.
Attach steering shaft to stabiliser - counterhold at flattened areas using open-ended spanner - tightening torque 65 Nm / 48 lbf. ft.
For vehicles with xenon low beam headlamps: Attach ball head and wiring harness plug to vehicle level control sensor.
Attach lower engine compartment cover.
Attach front wheels – tightening torque 110 Nm / 81 lbf. ft.
Connect clutch actuation pressure line and fasten retaining band.
Connect brake servo vacuum line to intake plenum.
Attach vacuum line to intake plenum switchover valve solenoid with T-piece and connect intake plenum switchover valve T-piece to brake servo vacuum line.
Attach high pressure line to power steering pump with new O-ring – tightening torque 28 Nm / 20.5 lbf. ft.
Attach hydraulic hoses to power steering fluid reservoir.
Attach wiring harness plug.
Connect wiring harness plug to engine control unit.
Attach ground cable to engine control unit.
Close relay frame cover.
Connect refrigerant lines.
Attach vacuum line to shut-off valve.
Connect tank vent line.
Attach fuel lines to fuel distributor pipe adapter.
Attach hoses to engine vent adapter.
Attach all coolant hoses.
Install pre-volume chamber – see operation "Pre-volume Chamber, Remove and Install".
Connect multiplug (twist lock).
Install battery.
Connect positive cable to positive terminal and ground cable to ground terminal.
Insert fuse carrier and close.
Install radiator damper (3 pieces)
Charge air conditioning – see operation "Air Conditioning, Evacuate and Charge" in group "D".
Bleed hydraulic clutch actuation – see operation "Hydraulic Clutch Actuation, Bleed " in group "K".
Charge power steering – see operation "Hydraulic System, Charge and Bleed" in group "M".
Inspect
Top up cooling system – see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".
1
) Clean thread and insert bolts with bolt locking compound (red).
2
) Use new bolts.