Engine, Remove and Install
Drain air conditioning - see operation "Air Conditioning System, Drain" in Group "D".
Disconnect battery negative lead - see operation "Battery Negative Lead, Disconnect and Connect" in Group "N".
Detach positive cable (1) from the central electrics housing.
Disconnect central connector (black) (2) from central electrics housing.
Disconnect ground cable (3) from body.
Lay central electrics housing and wiring harnesses to one side (make battery accessible).
Disconnect positive cable (1) from battery (2).
Disconnect vacuum hose (3) from distribution piece.
Disconnect wiring harness plug (5) from hot film mass air flow sensor.
Detach air intake hose with air intake pipe (8) from turbocharger, cylinder head cover and air cleaner housing and remove.
Lay solenoid valve bracket (6) to one side.
Detach intercooler pipe with intercooler hose (4) from turbocharger, cylinder head cover and intercooler.
Remove bracket for pre�glow unit (7) and lay towards the front.
Detach torque support (3) from respective main bracket and torque support brackets (4) and (7) from front crossmember.
Unhook hood lock Bowden cable (2) and lay to one side.
Disconnect wiring harness plug (1) from hood lock contact switch.
Remove hood lock retainer (5) and hood contact switch (6) from front crossmember.
Open coolant drain plug - collect coolant.
Detach upper coolant hose (1) from thermostat housing.
Detach coolant hoses (3) from coolant expansion tank.
Detach coolant expansion tank (4) from suspension turret strut and front crossmember.
Remove left�hand suspension turret strut (2).
Disconnect wiring harness plug from coolant level sensor.
Unclip upper part of air cleaner housing from lower part.
Detach wiring harness plug (1) from engine control unit, and take wiring harness out from lower part of air cleaner housing and lay towards the front.
Unclip engine control unit bracket (2) from lower part of air cleaner housing and take out with engine control unit (3).
Disconnect vacuum line from cover of lower part of air cleaner housing.
Remove bolts (4) and take out lower part of air cleaner housing.
Detach intercooler hose (1) from upper part of intake manifold and intercooler.
Disconnect wiring harness plug from both fan motors and uncover it.
Disconnect wiring harness plug (2) from air conditioning pressure sensor.
Disconnect wiring harness plugs (3) (4 plugs).
Detach refrigerant lines (5) from accumulator/dehydrator.
Detach refrigerant line (4) from condenser.
Unclip entire wiring harness from front crossmember and lay onto engine.
Detach brake servo vacuum line (1) from vacuum pump.
Disconnect heater body coolant lines (4) (quick�release couplings).
Disconnect leak�off pipe (arrow).
Detach the high�pressure pipe from the high�pressure pipe for the central release bearing on the clutch housing union (2) - to do this, release and remove the clip (3) with a screwdriver, then bend the clip slightly together and insert it back into the connector.
Disconnect fuel feed line (1) from fuel filter housing using KM�796.
Disconnect fuel return pipe (2) using KM�J�37088�A.
Pull both axle shafts out of wheel hubs (do not remove from gearbox) - see operation "Axle Shafts, Remove and Install" in Group "E".
Remove lower wheel housing trim on both sides. Disconnect wiring harness plug from wheel speed sensor on both sides. Remove engine undershield.
Remove the front exhaust pipe (3) with catalytic converter.
To prevent engine from tipping over: slightly swivel engine backwards and lay suitable block of wood (1) between compressor and front axle body.
Push rubber gaiter for steering column intermediate shaft upwards and remove clamp bolt (2) for intermediate shaft.
Push intermediate shaft off steering gear.
Loosen retaining bolt (1) for shift rod clamp and disconnect shift guide from shift rod.
Disconnect lower coolant hose (2) from radiator.
Install basic frame KM�904 (2) with centring mount KM�940 (1) on hydraulic jack and place it up against the front axle body - take care that guide pins are located in pilot holes.
Use of pulse or impact screwdrivers to remove and install the front axle body is not permitted. Note that the bolt lengths and plain washers are different.
Remove rear left and right�hand retaining bolts (3 - two bolts). Remove 2 front retaining bolts (4) on left and right�hand side.
Carefully lower front axle body with engine and gearbox - ensure that no attaching parts are damaged.
Insert new plastic sleeves into damping bushes to guide bolts.
Lift front axle body and engine/gearbox with the hydraulic jack, basic frame KM�904 and centring mount KM�940. Align front axle body and place in position flush with the chassis. Guide pins (1) and (2) must be seated in the pilot holes (arrows).
Use of pulse or impact screwdrivers to remove and install the front axle body is not permitted. Note that the plain washers and the bolt lengths are different. Insert new retaining bolts and tighten uniformly and finger tight at all mounting points.
Attach front axle body to chassis. Tighten retaining bolts on the right�hand side of the vehicle first - 180 Nm.
Remove hydraulic jack, basic frame KM�904 and centring mount KM�940.
Attach bottom coolant hose to radiator.
Push shift guide onto shift rod and tighten clamp bolt finger tight.
Slide the intermediate shaft onto the steering gear spindle (3). Coat the clamp bolt (2) with thread locking compound (red).
Before inserting the clamp bolt, ensure that the rear groove (arrow) on the steering gear spindle lines up with the bore on the intermediate shaft.
Attach the intermediate shaft to the steering gear spindle with the clamp bolt - 45 Nm.
Push sleeve (1) onto steering gear - ensure that it is seated properly.
Connect wiring harness plug to wheel speed sensor on both sides.
Install axle shafts in wheel hubs on both sides - see operation "Axle Shafts, Remove and Install" in Group "E".
Remove block of wood between compressor and front axle body. Install lower wheel housing trim on both sides.
Lay entire wiring harness in roughly the correct position.
Connect fuel return line (2).
Attach fuel supply line (1) to fuel filter housing. Connect fuel leak�off pipe.
Attach pressure line with connection piece (3) to pressure line for central release cylinder on clutch housing - engages audibly.
Connect coolant lines to heater body (1) (quick release couplings) - must click as they snap in place.
Attach brake servo vacuum line (2) to vacuum pump.
Attach rear refrigerant line (6) to accumulator/dehydrator (threaded connection) - torque 47 Nm.
Attach side refrigerant line (5) to accumulator/dehydrator (block�fitting) - torque 16 Nm.
Attach lower refrigerant line (4) to condenser - torque 27 Nm.
Attach upper refrigerant line (3) to condenser - torque 16 Nm.
Connect wiring harness plug (2) to air conditioning pressure sensor.
Connect 3 wiring harness plugs.
Clip wiring harness into front crossmember.
Connect wiring harness plug to both fan motors.
Attach intercooler hose (1) to upper part of intake manifold and intercooler.
Attach lower part of air cleaner housing to body using retaining bolts (1) - 10 Nm.
Clip engine control unit bracket (2) with engine control unit (3) into lower part of air cleaner housing.
Attach wiring harness plug (4) to engine control unit and insert wiring harness into lower part of air cleaner housing and route.
Clip upper part of air cleaner housing to lower part. Attach suspension turret strut to body - torque 47 Nm.
Connect wiring harness plug to coolant level sensor and attach coolant expansion tank to suspension turret strut and front crossmember.
Attach coolant hoses to coolant expansion tank. Connect upper coolant hose to thermostat housing.
Attach hood lock retainer and hood contact switch to front crossmember.
Connect wiring harness plug to hood contact switch. Hook hood lock Bowden cable in place.
Attach torque supports with new retaining nuts to respective main bracket - torque 53 Nm.
Attach torque support bracket to front crossmember - torque 26 Nm.
Attach bracket for pre�glow unit.
Push on solenoid valve bracket.
Attach intercooler pipe with intercooler hose to turbocharger, cylinder head cover and intercooler.
Attach air intake hose with air intake pipe to turbocharger, cylinder head cover and air cleaner housing, and secure with retaining bracket.
Connect wiring harness plug to hot film mass air flow sensor.
Connect battery positive terminal.
Connect ground cable to body.
Connect central connector (black) to central electrics housing.
Attach positive cable to the central electrics housing.
Connect ground cable to battery.
Install the front exhaust pipe with catalytic converter.
Charge air conditioning system - see operation "Air Conditioning System - Evacuate and Charge" in group "D".
Bleed clutch hydraulics - see operation "Hydraulic Clutch Controls, Bleed" in Group "K".
Adjust gearshift linkage - see operation "Gearshift Linkage, Adjust" in Group "K".
Fill cooling system - see operation "Cooling System, Fill and Bleed" and "Cooling System, Check for Leaks".
Bleed fuel system - see operation "Fuel System, Bleed" in Group "L".
Check the straight ahead position - see operation "Checking and Adjusting the Straight Ahead Position" in Group "M".
Check camber, castor and toe�in, adjust if necessary - see operation "Axle, Measure" and "Toe�in, Adjust".