Engine, Remove and Install
Drain air conditioning system - see operation "Air Conditioning System, Drain" in Group "D".
Disconnect ground cable from battery - see operation "Battery Ground Cable, Disconnect and Connect" in Group "N".
Remove washer fluid reservoir - see operation "Washer Fluid Reservoir, Remove and Install" in Group "N".
Detach positive cable (1) from central electrical box.
Detach lower cover from central electrical box.
Disconnect central connector (2) (brown) and central connector (3) (black) from central electrical box.
Lay cable bundles to one side.
If fitted, disconnect the wiring harness plug (1) (orange lead) from the central electrical box - note installation position.
Disconnect wiring harness plug (2) (red lead) from central electrical box - note installation position.
Disconnect wiring harness plug (3) (black/white) - wiring harness plug is near the battery.
Disconnect battery positive terminal (4).
Remove battery (5).
Open coolant drain plug (3) on radiator - collect coolant.
Detach upper coolant hose (4) from radiator and thermostat housing.
Disconnect wiring harness plug (1) from thermoswitch(es) and wiring harness plug (2) from compressor.
Detach torque supports (5) from main bracket and detach brackets (6) from air deflector panel - remove both torque supports with their brackets.
Disconnect wiring harness plug (1) from bonnet lock contact switch.
Unhook Bowden cable for bonnet lock.
Remove fastening bolts (3) and take off bonnet lock support.
Up to '99 MY: disconnect wiring harness plugs (2) from both fan motors.
From '99 MY: disconnect fan motor wiring harness plugs.
Detach coolant hoses (1) and (2) from coolant compensation tank.
Detach coolant compensation tank from front suspension brace (3) and detach air deflector panel.
Detach front suspension brace from body.
Reduce fuel pressure with Fuel Pressure Gauge KM�J�34730�91 via test connection - collect escaping fuel in suitable container - observe safety regulations and national legislation.
Disconnect fuel lines (4) using KM�J 37088�A.
Disconnect wiring harness plug (5) from intake air temperature sensor.
Disconnect air intake hose (6) from air intake pipe.
Detach upper part of air cleaner housing (1).
Take out engine control unit (2) with cable bundle.
Disconnect wiring harness plug (4) from engine control unit.
Detach lower part of air cleaner housing (3) from body and remove complete with air intake hose.
Disconnect wiring harness plugs (3 multiplugs) (1).
Disconnect wiring harness plug from wheel speed sensor.
Pull wiring harness plug (2) off both air conditioning pressure switches.
Detach complete cable bundle from air deflector panel and lay in a suitable place.
Disconnect refrigerant line (1) from condenser and refrigerant line (2) from accumulator/dryer - seal refrigerant lines and connections with suitable plugs.
Disconnect oxygen sensor wiring harness plug.
Detach the high�pressure pipe and connector (3) from the high�pressure pipe for the central release bearing on the clutch housing - to do this, release and remove the clip (4) with a screwdriver, then bend the clip together slightly and insert it back into the connector.
Detach the engine vent hose (1) from the cylinder head cover.
Unclip accelerator actuation Bowden cable (2) from ball head and bracket.
Detach air intake pipe (3) from throttle body and from resonator - see illustration "Air Ducts".
Pull vacuum hose (1) off tank vent valve and seal it.
Detach brake servo vacuum line (2) from intake manifold.
Detach coolant hoses (1) from coolant flange (DIS ignition module adapter) and from coolant pipe/heat exchanger (quick�release couplings) - see operation "Coolant Hoses, Replace - X 22 XE Engine" in Group "D".
Lay any cable bundles connected to the engine on the engine and fasten them.
Vehicles fitted with an airbag: turn steering wheel to straight ahead position, remove ignition key and apply steering lock.
Pull axle shafts on both sides out of the wheel hubs - see operation "Axle Shafts, Remove and Install" in Group "E".
Remove front left wheel well panelling.
Detach vacuum hose (2) and (4) from secondary air solenoid and air duct hose (3) from secondary air pump.
Push rubber gaiter for steering column intermediate shaft upwards and remove clamp bolt (1) for intermediate shaft.
Slide intermediate shaft off steering gear.
Loosen fastening bolt (2) for shift rod clamp and disconnect shift guide from shift rod.
Remove bottom coolant hose (3) from radiator.
Remove front exhaust pipe with catalytic converter.
To prevent the engine from tipping: tilt engine backwards slightly and insert a suitable wooden block (1) between compressor and front axle body.
Install basic frame KM�904 (2) with centring mount KM�940 (1) on hydraulic jack and place snugly under front axle body - take care that guide pins are located in pilot holes.
Mounting and dismounting the front axle body using a pulse or impact screwdriver is not permitted. Note different bolt lengths and washers.
Remove two rear left and right�hand fastening bolts (3). Remove two front left and right�hand fastening bolts (4).
Carefully lower front axle body with engine and transmission - ensure that no attaching parts are damaged.
Insert new plastic sleeves into damping bushes to guide bolts.
Lift front axle body and engine/transmission with the hydraulic jack, basic frame KM�904 and centring mount KM�940. Align front axle body and place flush on chassis. Guide pins (1) and (2) must be located in pilot holes (arrows).
Mounting and dismounting the front axle body using a pulse or impact screwdriver is not permitted. Note that the plain washers and the bolt lengths are different. Insert new fastening bolts and tighten uniformly and finger tight at all fastening points.
Attach front axle body to chassis. Tighten fastening bolts on the right�hand side of the vehicle first - tightening torque 160 Nm.
Remove hydraulic jack, basic frame KM�904 and centring mount KM�940.
Install front exhaust pipe using new gaskets and new fastening nuts.
Attach bottom coolant hose to radiator.
Push shift guide onto shift rod and tighten clamp bolt finger tight.
Attach intermediate shaft to steering gear - see operation "Intermediate Shaft, Remove and Install" in Group "M".
Attach vacuum hoses and air duct hose to secondary air pump.
Insert axle shafts in wheel hubs on both sides - see operation "Axle Shafts, Remove and Install" in Group "E".
Attach coolant hose to coolant flange (DIS ignition module adapter) and to coolant pipe/heat exchanger, quick�release couplings must engage audibly - see operation "Coolant Hoses, Replace - X 22 XE Engine" in Group "D".
Attach vacuum hose to tank vent valve and brake servo vacuum line to intake manifold.
Attach air intake pipe to throttle body and resonator, ensuring it is correctly seated - see illustration "Air Ducts".
Attach engine vent hose to cylinder head cover.
Clip accelerator actuation Bowden cable into ball head and bracket.
Insert high�pressure line. Attach high�pressure pipe with connector to high�pressure pipe for central release bearing on clutch housing - engages audibly.
Connect oxygen sensor wiring harness plug.
Attach refrigerant lines to accumulator/dryer and condenser - tightening torque 16 Nm.
Connect wiring harness plugs to both air conditioning pressure switches.
Connect left�hand wheel speed sensor wiring harness plug.
Connect wiring harness plugs (3 multiplugs).
Attach air cleaner housing to boday and air intake hose to air intake pipe - see illustration "Air Ducts".
Connect wiring harness plug to intake air temperature sensor.
Connect fuel lines.
Connect wiring harness plug to engine control unit.
Fit engine control unit in air cleaner housing and attach cover.
Fit left�hand front suspension brace to suspension strut - tightening torque 47 Nm.
Attach left�hand front suspension brace to air deflector panel - tightening torque 25 Nm.
Fasten coolant compensation tank to front suspension brace and air deflector panel.
Attach coolant hoses to coolant compensation tank.
Connect wiring harness plugs to bonnet contact switch and fan motors.
Connect Bowden cable to bonnet lock and bonnet lock support to body.
Attach both torque supports, with new fastening nuts, to main bracket - tightening torque 53 Nm.
Attach torque support brackets to air deflector panel - tightening torque 26 Nm.
Connect wiring harness plugs to thermoswitch(es) and compressor.
Close coolant drain plug on radiator. Attach upper coolant hose to radiator and thermostat housing.
Connect right�hand wheel speed sensor wiring harness plug.
Install battery. Connect battery positive terminal.
Connect wiring harness plug (black/white) - wiring harness plug is near the battery.
Make connections at the central electrical box.
Attach lower cover to central electrical box.
Attach positive cable to central electrical box.
Install washer fluid reservoir - see operation "Washer Fluid Reservoir, Remove and Install" in Group "N".
Connect ground cable to battery - see operation "Battery Ground Cable, Disconnect and Connect" in Group "N".
Fill air conditioning system - see operation "Air Conditioning System, Evacuate and Fill" in Group "D".
Bleed clutch hydraulic system - see operation "Hydraulic Clutch Controls, Bleed" in Group "K".
Adjust gearshift mechanism - see operation "Gearshift Linkage, Adjust" in Group "K".
Fill up cooling system - see operations "Cooling System, Fill and Bleed" and "Cooling System, Check for Leaks".
Check camber, castor and toe�in and, if necessary, adjust toe�in - see operations "Camber, Castor and Toe�in, Check" and "Toe�in, Adjust" in Group "E".