Engine Without Transmission, Remove and Install (C 20 XE Without Pot Flywheel)
Remove, Disconnect Disconnect ground cable from battery. Remove bonnet - see operation "Bonnet, Bonnet Functioning Parts, Remove and Install" in group "A". Remove lower coolant hose from radiator - collect coolant. Disconnect wiring harness plug for fan motor. Detach air intake hose (1) from air cleaner housing. Disconnect wiring harness plug (2) from mass air flow meter. Detach hose (arrow) from prevolume chamber (3) and remove prevolume chamber with air intake hose. Detach upper coolant hose from radiator and thermostat housing. Disconnect wiring harness plug (4) from coolant temperature sensor and wiring harness plug (5) from coolant temperature sender. |
|
Remove, Disconnect Remove performance header - see operation "Performance Header, Remove and Install (C 20 XE)". Disconnect wiring harness plug and high voltage cable from high voltage distributor. Detach coolant hose from cylinder head and coolant hoses from coolant pipe. Disconnect multipin plug. Disconnect wiring harness plug from reversing light. Disconnect engine - bodywork multipin plug (twist cap). |
|
Remove, Disconnect Detach accelerator Bowden cable from curved disc and lay aside to rear. Close off fuel lines with spring clamps and detach from fuel distributor pipe. Remove engine vent hoses (arrows) from cylinder head cover. Remove plug strip from injectors. Disconnect wiring harness plug (1) from throttle valve potentiometer, ground connections (2) from fuel distributor pipe and wiring harness plug (3) from tank vent valve. Lay plug strip aside to rear. Detach vacuum hose from tank vent valve. Detach brake servo vacuum line from intake manifold. Remove alternator - see operation "Alternator, Remove and Install". Detach coolant hoses from coolant compensation tank. |
|
Remove, Disconnect Detach clutch cable from clutch release lever. Loosen fastening bolt (1) and remove shift rod from shift guide. Attach engine to Engine Bridge KM-263-B or MKM-883-1. Remove fastening bolts for intermediate shaft bracket (arrows) from cylinder block. |
|
Remove, Disconnect Remove V-belt pulley from toothed belt drive gear - counterhold on fastening bolt of toothed belt drive gear. Remove oil filter with KM-726-A, placing drip pan underneath. For version with oil cooler: Remove oil cooler lines from adapter. If present: disconnect wiring harness plug for dynamic oil level control. Remove pressure plate and clutch disc - see operation "Pressure Plate and Clutch Disc, Remove and Install" in group "K". |
|
Remove fastening bolts (1) from cylinder block and fastening bolts (2) from side member - remove front right engine damping block with bracket. |
|
Remove, Disconnect Remove lower transmission fastening bolts from cylinder block. Support engine with jack and remove Engine Bridge KM-263-B or MKM-883-1. Hang engine from workshop crane. Remove upper transmission fastening bolts from cylinder block. Press off engine from transmission and lift upwards out of engine compartment.
Install, Connect Lower engine into engine compartment and insert guide bushings of cylinder block into transmission. Attach upper transmission fastening bolts to cylinder block - 60 Nm/44 lbf. ft. Attach engine to Engine Bridge KM-263-B or MKM-883-1. |
|
Install, Connect Attach lower transmission fastening bolts to cylinder block - 60 Nm/44 lbf. ft. Attach engine damping block to longitudinal bracket - Regroove thread and insert screws with screw lock (red) tightening torque 65 Nm. Attach engine damping block bracket to cylinder block - 60 Nm/44 lbf. ft. Install pressure plate and clutch disc - see operation "Pressure Plate and Clutch Disc, Remove and Install" in group "K". If present: connect wiring harness plug for dynamic oil level control. Version with oil cooler: attach oil cooler lines to adapter with new seal rings - 30 Nm/22 lbf. ft. Coat seal ring of new oil filter slightly with engine oil and attach to oil pump - 15 Nm/11 lbf. ft. Attach V-belt pulley to toothed belt drive gear - counterhold on fastening bolt of toothed belt drive gear - 20 Nm/15 lbf. ft. Attach intermediate shaft bracket to cylinder block - 55 Nm/41 lbf. ft.
Install, Connect Insert shift rod in shift guide - tighten to torque after adjustment of transmission shift linkage. Attach clutch cable to clutch release lever. Attach coolant hose to coolant compensation tank. Alternator - see operation "Alternator, Remove and Install". Attach brake servo vacuum line to intake manifold - 20 Nm/15 lbf. ft. Connect vacuum hose to tank vent valve. Connect wiring harness plug to throttle valve potentiometer, ground connections to fuel distributor pipe, wiring harness plug to tank vent valve and plug strip to injectors - ensure correct seating. Attach engine vent hoses to cylinder head cover. Attach fuel lines to fuel distributor pipe and remove spring clamps. Attach accelerator Bowden cable to curved disc.
Install, Connect Plug in engine - bodywork multipin plug (twist cap). Connect wiring harness plug to reversing lamps switch. Attach coolant hose to cylinder head and coolant hoses to coolant pipe. Plug in multipin plug. Attach wiring harness plug and high voltage cable to high voltage distributor. Install performance header - see operation "Performance Header, Remove and Install (C 20 XE)". Connect wiring harness plugs to coolant temperature sensor and coolant temperature sender. Attach upper coolant hose to radiator and thermostat housing.
Install, Connect Attach engine vent hose to prevolume chamber and install prevolume chamber with air intake hose. Connect wiring harness plug to mass air flow meter. Attach air intake hose to air cleaner housing. Connect wiring harness plug to fan motor. Attach lower coolant hose to radiator. Install bonnet - see operation "Bonnet, Bonnet Functioning Parts, Remove and Install" in group "A". Connect ground cable to battery.
Adjust Adjust shifting - see operation "Transmission Shift Linkage, Adjust" in group "K".
Inspect Cooling system - see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".
|