Note. The operation is described for a vehicle with air conditioning, for vehicles without air conditioning proceed analogously. Cable ties which are released or detached for removing the engine must be re-installed in the same position during the installation procedure.
Remove
Drain air conditioning - see operation "Air Conditioning, Drain" in group "D".
Disconnect wiring harness plug (1) from intake air temperature sensor. Detach engine vent hose (3) from cylinder head cover. Detach vacuum line (4) of fuel pressure regulator for air intake pipe from air intake pipe. Unclip vacuum line (6) from air intake pipe. Release hose clamp (5).
Unclip cable (2) for tank vent valve and intake air temperature sensor from upper part of air cleaner housing. Detach tank vent valve (7) from upper part of air cleaner housing. Detach wiring harness plug (8) and lay tank vent valve aside.
Remove
Unclip upper part of air cleaner housing from lower part of air cleaner housing. Remove upper part of air cleaner housing with air intake pipe from lower part of air cleaner housing and from throttle body. Release fastening nuts (arrows) and remove lower part of air cleaner housing.
Detach ground cable (1) from ground terminal (2) Remove ground terminal (2) from battery.
Disconnect positive cables (5) and (6) from positive terminal (4) and positive terminal (4) from battery.
Disconnect relay/fuse box (3) from bracket and lay aside.
Remove
Remove battery (2). Disconnect ground cable (4) from body. Disconnect multiplug (1) (twist lock).
Unclip compensation tank coolant hose (5) and detach from coolant compensation tank.
Detach coolant hose (3) from coolant compensation tank.
Detach fastening clips for wiring harness (9) from fuse box bracket (7). Detach multiplug (6) (twist lock) - lay wiring harness aside.
Detach battery support (8) from body and remove.
Remove coolant drain bolt from coolant pump (accessible from underside of vehicle) - collect escaping coolant.
Install
Install coolant drain bolt in coolant pump - tightening torque 20 Nm / 15 lbf. ft.
Note. Before detaching the lower coolant hose from the coolant compensation tank, guide marks must be provided, as shown in Illustration J 1205.
Caution
It is only ensured that the engine is completely bled and that no air pockets remain in the cooling system if the coolant hose is in its correct installation position.
Remove
Remove lower coolant hose (1) from coolant compensation tank and from radiator.
Remove
For version with manual transmission: Detach pressure line with connector (1) from central release pressure line at clutch housing - to do this, release clamp (2) with screwdriver and remove; then bend clamp together again slightly and insert into connector.
Carefully press off both shift cables (3) from ball heads from below with KM-6042. Compress plastic clamps (4) and remove shift cables from shift cable bracket.
For version with automatic transmission: Remove retaining clamp (6) using suitable screwdriver. Press off selector lever actuating cable (5) from actuating lever and unclip from counterhold (arrow).
Remove
For version with automatic transmission: Release and disconnect wiring harness plug (3) for selector lever position switch. Unclip automatic transmission bleeder hose (2) from bracket on relay frame cover and expose.
Detach brake servo vacuum line at quick fitting (1)
Detach vacuum line at specified location (4)
Remove
Detach wiring harness plug (1) for mixture regulation oxygen sensor.
Disconnect wiring harness plug (2) of oxygen sensor for catalytic converter check and expose cable of oxygen sensor for catalytic converter check.
Disassemble
Disassemble wiring harness plug of oxygen sensor for catalytic converter check - note cable occupancy: Disconnect cable retainer from wiring harness plug: Release cable with MKM-923-8 and pull out of wiring harness plug.
Caution
Cable occupancy:
4 = first white cable - mark with insulating tape (3),
3 = second white cable,
2 = black cable,
1 = grey cable.
Install
Connect separate cable to cable of oxygen sensor for catalytic converter check - carefully pull cable through downwards.
Remove
Release coolant hoses (1) and disconnect from coolant cut-off valve, i.e. from quick fittings.
Remove fastening nut (arrow) and disconnect refrigerant line (4) from pulsation damper (3).
Remove both refrigerant line fastening clamps (2) from refrigerant line bracket at cylinder head cover.
Caution
Fuel escapes. Observe safety regulations and national legislation.
Install
Connect Fuel Pressure Gauge KM-J-34730-91 to test connection (2) on fuel distributor pipe. Reduce fuel pressure by opening valve on pressure gauge - collect escaping fuel in suitable container.
Remove
Detach fuel feed line (3) and fuel return line (1) from fuel distributor pipe - lay fuel lines aside to the rear.
Release right wiring harness plug (6) for engine control unit and detach from engine control unit. Unclip cable bundle (4), expose and lay aside.
Disconnect vacuum line for tank vent valve at quick fitting (5) from intake manifold.
Remove fastening nut (arrow) and disconnect refrigerant line at block connection.
Detach both radiator retaining brackets (7) left and right from air deflector panel.
Remove
Remove fastening bolts (1) and detach lower heat shield from upper heat shield.
Disconnect both front wheels.
For version with xenon headlamps: Disconnect wiring harness plug (2) from vehicle level control sensor and unclip cable (arrow). Carefully unclip actuation linkage (3) from vehicle level control sensor.
Remove radiator grille and front panelling - see operation "Front Panelling, Remove and Install" in group "A".
Caution
For vehicles with airbag: Turn steering to straight ahead position, remove ignition key and engage steering lock.
Remove
Remove intermediate steering spindle clamp bolt (1) (passenger compartment).
Remove pendulum (2) on both sides from spring strut support tube - counterhold with open-ended wrench at two flattened points.
Pull axle shafts out of wheel hub (do not detach from transmission) - see operation "Axle Shafts, Remove and Install" in group "E".
Lay aside cable of oxygen sensor for mixture regulation.
Remove front exhaust pipe/catalytic converter.
Remove
Unclip fluid feed line and fluid return line (2) for power steering pump out of bracket on front axle body. Insert KM-6173 (1), align and turn upwards until it bears against cylinder block.
Remove fastening nuts (3) and (5) and remove upper engine damping block bracket (4).
Remove
Construct Base Frame KM-904 (2) with Centring Mount KM-905 (1) on hydraulic jack and place without clearance under front axle body (use hydraulic jack which can be lowered to at least 100 cm).
Caution
Removal with pulse or impact screwdriver not permitted. Note different bolt lengths and washers.
Note. For greater clarity, illustration F 8464 shows the front axle body without hydraulic jack and centring locator.
Remove
Remove fastening bolts (1) (4 off). Remove fastening bolts (2) (4 off). Remove fastening bolts (3) (2 off).
Carefully lower front axle body with entire drive unit, steering gear and radiator - thereby ensuring that no attaching parts are damaged.
Caution
Before installing the front axle body with drive unit: check thread of locking nuts (fastening bolts 1-3) for ease of movement, replace locking nuts if necessary - see operation " Replacement Locking Nuts" in group "A".
Install
Carefully insert front axle body with entire drive unit, steering gear and radiator in engine compartment and position free of play on chassis - use hydraulic jack, Base Frame KM-904 and Centring Mount KM-905. Thereby ensure that no attaching parts are damaged.
Attach front axle body to chassis with new fastening bolts - note different bolt lengths (1 and 3: long bolts, 2: short bolts) - tightening torque 100 Nm / 74 lbf. ft. + 45 ° + 15 ° 1) 2) . Use torque wrench and KM-470-B.
Caution
Installation with an impact screwdriver is not permitted. Note different bolt lengths and washers.
Install
Attach front exhaust pipe/catalytic converter with new fastening nuts, new fastening bolts and new gasket to exhaust manifold and to front muffler - tightening torque 16 Nm / 12 lbf. ft. Route cable of oxygen sensors and clip to the points provided - route cable of oxygen sensors so that abrasion cannot occur and that they cannot contact the exhaust.
Install axle shafts - see operation "Axle Shafts, Remove and Install" in group "E".
Attach swing arms on both sides to spring strut support tube with new fastening nuts - counterhold with open-ended spanner at two flattened surfaces - tightening torque 65 Nm / 48 lbf. ft.
Install front panelling and radiator grille - see operation "Front Panelling, Remove and Install" in group "A".
For version with xenon headlamps: Connect wiring harness plug to level control sensor and clip in cable. Clip actuation linkage to vehicle level control sensor.
Attach both front wheels - tightening torque 110 Nm / 81 lbf. ft.
Insert upper engine damping block bracket, attach to engine damping block and to front right engine damping block bracket (5 fastening nuts) and hand-tighten all fastening nuts. Detach KM-6173 from front axle body. Clip fluid feed line and fluid return line for power steering pump into bracket on front axle body. Tighten upper engine damping block bracket using the 5 fastening nuts - tightening torque 60 Nm / 44 lbf. ft.
Install
Attach radiator to air deflector panel using the two retaining brackets.
Insert lower heat shield and attach to upper heat shield.
Tightening torque 8 Nm
Connect refrigerant line (front) with new gasket to refrigerant line block connection - tightening torque 20 Nm / 15 lbf. ft. Attach refrigerant line to refrigerant line bracket using the two fastening clamps (on the cylinder head cover). Attach pulsation damper to refrigerant line - tightening torque 20 Nm / 15 lbf. ft.
Place cable bundle for right wiring harness plug of engine control unit onto wiring trough and clip securely. Connect wiring harness plug and slide onto wiring harness plug bracket on wiring trough. Connect right wiring harness plug to engine control unit and lock - ensure correct seating of wiring harness plug.
Connect fuel feed line and fuel return line to fuel distributor pipe. Clip fuel lines into fuel line bracket.
Note. Before assembling components of the intake system (hoses, connections, etc.), they must be cleaned of any possible contamination (grease, oil, etc.). When tightening the hose clamps, be sure to observe exactly the tightening torque of 3.5 Nm / 2.6 lbf. ft.
Caution
It is only ensured that the intake system is free of leaks, thus ensuring operational safety of the engine, if the hose clamps are tightened correctly to the prescribed tightening torque.
Install
Insert lower part of air cleaner housing and secure using the two fastening nuts.
Attach vacuum line of tank vent valve for intake manifold to quick fitting on intake manifold.
Position upper part of air cleaner housing with air intake pipe onto lower part of air cleaner housing and clip securely. Attach air intake pipe to throttle body and tighten hose clamp.
Connect wiring harness plug to tank vent valve. Attach tank vent valve to upper part of air cleaner housing. Clip cable for tank vent valve and intake air temperature sensor into upper part of air cleaner housing.
Clip vacuum line into air intake pipe.
Connect vacuum line of fuel pressure regulator for air intake pipe to air intake pipe.
Install
Attach engine vent hose to cylinder head cover.
Connect wiring harness plug to intake air temperature sensor.
For version with automatic transmission: Clip selector lever actuation cable into counterhold and attach to actuation lever for selector lever. Insert retaining clip. Connect wiring harness plug to selector lever position switch and lock.
For version with manual transmission: Attach delivery connection for hydraulic clutch actuation to manual transmission. Insert both shift cables into shift cable bracket and allow plastic clamps to engage. Attach shift cables to ball heads.
Assemble wiring harness plug of oxygen sensor for catalytic converter check - note cable routing.
Connect wiring harness plug of oxygen sensor for mixture regulation.
Install
Connect both coolant hoses at the quick fittings and lock.
Connect vacuum line (of intake manifold to accumulator) at specified position.
Connect brake servo vacuum line at quick fitting.
Attach lower compensation tank coolant hose to coolant compensation tank - ensure correct installation location.
Caution
It is only ensured that the engine is completely bled and that no air pockets remain in the cooling system if the coolant hose is in its correct installation position.
Install
Connect multiplug (twist lock) and lock. Connect ground cable to body.
Install
Attach upper compensation tank coolant hose to radiator.
Attach battery support to body. Attach fuse box bracket to battery support.
For version with automatic transmission: Clip automatic transmission bleeder hose into relay frame cover.
Clip cable bundle to fuse box bracket, connect multiplug (twist lock) and lock.
Attach both upper compensation tank coolant hoses to coolant compensation tank and clip into bracket.
Install battery. Attach all cable connections to battery/battery terminals. Connect fuse box/relay box to battery bracket.
Attach steering intermediate shaft to steering gear (interior) using new fastening bolt - tightening torque 22 Nm / 16 lbf. ft. + 45 ° + 15 ° 3) .
Charge air conditioning - see operation "Air Conditioning, Evacuate and Charge" in group "D".
Top up cooling system - see operations "Cooling System, Top up and Bleed" and "Cooling System, Check for Leaks".
For version with manual transmission: Bleed hydraulic clutch - see operation "Hydraulic Clutch Actuation with Brake Bleeder, Bleed" in group "K".
1
) Use new fastening bolts.
2
) Insert fastening bolts with screw locking compound (red). The installation time including torque check is max. 5 min.
3
) Re-cut thread for steering intermediate shaft before re-use. Insert new fastening bolt with screw locking compound (red). The installation time including torque check is max. 5 min.