Engine, Remove and Install
Remove
2. |
Remove steering column interim spindle
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Move steering wheel to straight-ahead position
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Remove ignition key and engage steering lock
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3. |
Remove air cleaner housing
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Disconnect mass air flow sensor wiring harness plug (2)
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Unclip tank vent line (3)
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Detach engine vent hose (4) from air intake hose
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Detach air intake hose (5) from throttle valve body
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Detach air cleaner housing
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Unclip rubber mounting at the bottom
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Remove air intake pipe (6)
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4. |
Detach earth cable
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Detach earth cables (4) and (5) from earth terminal (3)
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Detach earth connection from negative terminal
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5. |
Detach positive cable
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Detach positive cable (2) from positive terminal (1)
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Detach positive connection from positive terminal
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6. |
Remove battery
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Unscrew bolt (1)
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Remove retaining plate (2)
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7. |
Remove battery support (2)
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8. |
Detach tank vent valve hose (1) from tank vent valve
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9. |
Release fuel pressure with KM-J-34730-91 (2) via test connection
Note: Collect exiting
fuel in a suitable container - observe safety regulations and
national legislation
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Remove protective cap (1)
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10. |
Detach fuel supply line (2) with KM-796 (1) from fuel distributor pipe
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Disconnect quick-release fitting
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11. |
Detach brake servo vacuum line (3) from intake manifold
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Disconnect quick-release fitting
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12. |
Disconnect engine wiring harness
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Disconnect wiring harness plug (1)
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Release retainer in direction of arrow
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Disconnect wiring harness plugs (2) from engine control unit
(4)
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Unclip 3x wiring harnesses
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13. |
Disconnect wiring harness plug (1), reversing light switch
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14. |
Disconnect wiring harness plug, earth connection (1)
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Release retainer in direction of arrow
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15. |
Remove coolant expansion tank (1)
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Pull out of bracket in direction of arrow
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16. |
Disconnect steering wiring harness
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Remove fuse carrier cover
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Detach positive cable (2) from fuse carrier
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Disconnect wiring harness plug (1)
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Expose wiring harness
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Unclip 3x wiring harnesses
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17. |
Detach pressure hose, central release (2)
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Place collecting pan underneath.
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Unlatch retaining clamp (1) with screwdriver and detach
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Bend clip together a little and insert back into connecting
piece
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Tie up pressure line for central release
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19. |
Raise vehicle by half its height
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21. |
Remove radiator grille
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Remove 4x body-bound rivets (1)
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Unclip radiator grille (2) upwards from front panelling
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22. |
Raise vehicle by half its height
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23. |
Undo front panelling (1)
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Remove 5x body-bound rivets (3)
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24. |
Remove front panelling
Note: Second man
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Push front panelling upwards in direction of arrow and pull out
of bracket
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Unclip outside temperature sensor
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25. |
Remove right engine splash guard (2)
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Remove 2x body-bound rivets (3)
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26. |
Detach swing arm (2) from spring strut support tube
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Unscrew 2x nuts
Note: Use spanner (1)
to hold against flat surface
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27. |
Detach tie rods from steering knuckle with KM-507-C (3)
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28. |
Detach guide joints (4) from steering knuckle
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Expand steering knuckle bolts with KM-915
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Pull guide joints out of steering knuckle
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29. |
Remove axle shafts from wheel hub
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Unscrew 2x nuts
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Counterhold at wheel hub with KM-468-B (1)
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30. |
Raise vehicle by half its height
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31. |
Drain coolant
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Place collecting pan underneath.
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Attach suitable hose to drain connection (2)
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Open coolant drain screw (1)
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Close coolant drain screw
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32. |
Disconnect cooling module wiring harness plug (1)
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33. |
Disconnect wiring harness plug of catalytic converter control
oxygen sensor (1)
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34. |
Detach clamp (1) from shift rod
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Detach shift guide from shift rod
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35. |
Remove end silencer (1)
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Slacken fastening clamp (3)
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Remove from bracket
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Detach 2x rubber bearings (2)
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Detach end silencer from front silencer
Note: Second man
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36. |
Detach front exhaust pipe (2) from catalytic converter
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37. |
Remove front exhaust pipe with front silencer
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Unhook 2x rubber bearing (1)
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38. |
Insert KM-6173 (3)
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Slacken 4x bolts (arrows) and hand-tighten
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Align KM-6173 at front axle body
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Wind up the support bearing (1)
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Journal (2) must sit in mount at cylinder block
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39. |
Attach KM-6001-A (1)
Note: Attaching KM-6001-A guarantees perfect alignment of the
drive unit with the front axle body
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Slacken 3x bolts (arrows) in adjusting rails
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Insert KM-6001-A
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The journals (2) and (5) must sit in the guide holes of the
front axle body
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Tighten 3x bolts in adjusting rails
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Adjust support bearings, front (4) and rear (3)
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Raise support bearings up to the stop on the guide journals
Note: The guide
journals must be seated free from play in the support bearings
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40. |
Lower vehicle by its full height
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41. |
Detach coolant hoses (1) from heater core
Note: Mark assignment
using coloured markings
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Place collecting pan underneath.
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Release 2x quick-release fittings in direction of arrow
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42. |
Detach right engine damping block from engine damping block
bracket
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43. |
Detach left engine damping block from engine damping block
bracket
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44. |
Raise vehicle by its full height
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45. |
Attach KM-904 with KM-6390
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Attach to hydraulic lifter
Note: Use hydraulic
jack that can be lowered to a height of at least 100 cm
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Lower centring pins (1)
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Place under front axle body, ensure there is no play
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Centring pins (2) must engage in the relevant holes in the
front axle body
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Important: It is not permissible
to disassemble the front axle body with an impulse or impact
screwdriver
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46. |
Remove front axle body
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Unscrew 10x bolts (1, 2, 3, 4)
Note: Note different
bolt lengths
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Important: Ensure that no
attached parts are damaged
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47. |
Move out front axle body
Note: 2 people
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Install
48. |
Check thread
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Check ease of movement of 10x cage nuts, replacing if
necessary
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49. |
Lock shift rod
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Turn shift rod (1) in the direction of the arrow
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At the same time, cause the locking pin (2) to engage by
pressing it
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Important: Ensure that no
attached parts are damaged
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50. |
Move front axle body back in
Note: 2 people
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Important: It is not permissible
to assemble the front axle body with an impulse or impact
screwdriver
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51. |
Fit front axle body
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Tighten 10x bolt 90 Nm + 45° +
15°
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52. |
Detach KM-904 and KM-6390
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53. |
Lower vehicle by its full height
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54. |
Attach right engine damping block to engine damping block
adapter
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55. |
Attach left engine damping block to engine damping block
adapter
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Important: It is imperative to
adhere to the following assembly order
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56. |
Attach coolant hoses to heater core
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Fit 2x quick release fittings (1) onto heater core connection
port (2) as far as they will go
Note: Pay attention to
coloured markings
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Slide the 2x quick-release fitting catches (3) in the direction
of the arrow all the way to the stop by simultaneously pressing the
release buttons (4)
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The colour rings (5) must be visible
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Check that quick release fittings are correctly seated and that
the colour rings (5) are visible
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57. |
Raise vehicle by half its height
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58. |
Install axle shafts in wheel hub
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Insert guiding joint into steering knuckle
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Tighten 2x nut 150 Nm , slacken
45° , then tighten to 250 Nm
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Counterhold at wheel hub with KM-468-B
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59. |
Attach guide joint to steering knuckle
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Use new nuts
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Tighten 2x screwed joint 50 Nm
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60. |
Attach tie rods to steering knuckle
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Tighten 2x nut 30 Nm + 90° +
15°
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61. |
Attach swing arm to spring strut support tube
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Tighten 2x nut 65 Nm
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Use spanner to counterhold against flat surface
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62. |
Raise vehicle by half its height
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65. |
Insert front exhaust pipe with front silencer
Note: Second man
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Attach 2x rubber bearings
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66. |
Attach front exhaust pipe with front silencer to catalytic
converter
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67. |
Install rear silencer
Note: Second man
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Fit rear silencer to front silencer
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Attach 2x rubber bearings
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68. |
Connect wiring harness plug for catalytic converter control
oxygen sensor
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69. |
Attach wiring harness plug for cooling module
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70. |
Attach right engine splash guard
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Install 2x body-bound rivets
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71. |
Attach oil drain bolt to oil pan
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Tighten drain bolt 10 Nm
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72. |
Fit front panelling
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Second man
Note: Slide side front
panelling into bracket
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Clip in outside temperature sensor
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Install 5x body-bound rivets
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73. |
Install radiator grille
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Clip into front panelling
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Install 4x body-bound rivets
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76. |
Attach pressure line for central release
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77. |
Connect steering wiring harness
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Attach positive cable to fuse carrier
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Fix wiring harness plug
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78. |
Insert coolant expansion tank into bracket
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79. |
Attach earth cable to earth terminal
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Connect one wiring harness plug
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80. |
Attach positive cable to positive terminal
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81. |
Connect engine wiring harness
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Connect wiring harness plug to engine control unit
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Attach wiring harness plug to reversing light switch
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Connect wiring harness plug, engine wiring harness
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82. |
Attach brake servo vacuum line to intake manifold
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83. |
Attach fuel supply line to fuel rail
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Connect quick release fitting
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84. |
Attach vent hose to tank vent valve
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85. |
Insert shift lever fixing KM-527-A
(1) in shift lever housing
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Unclip cover of central console
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Detach shift lever cover from central console
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86. |
Raise vehicle by its full height
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87. |
Attach shift guide clamp to shift rod
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Tighten bolt 12 Nm + 180° to
225°
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88. |
Lower vehicle by its full height
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89. |
Vent hydraulic clutch actuator
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90. |
Install battery holder
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Attach wiring harness to battery support
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91. |
Install air cleaner housing
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Attach air cleaner housing to wheelhouse
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Attach air intake hose to throttle valve module
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Attach engine vent hose to timing case
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Attach wiring harness plug to hot film mass air flow meter
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92. |
Install battery
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Install battery bracket
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Attach positive connection to positive terminal
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Attach earth connector to negative terminal
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93. |
Tighten bolt, intermediate steering spindle 22 Nm
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Coat bolt with screw locking compound and insert
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94. |
Remove shift lever fixing
Note: Locking pin in
adjusting bore releases itself the first time the shift lever is
engaged in the direction "R"
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Draw KM-527-A out of shift lever
housing
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Clip shift lever cover into central console
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95. |
Check that gears shift correctly
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Check ease with which gear changes are made with the vehicle
stationary, the engine running and the clutch disengaged
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96. |
Fill with coolant and bleed
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97. |
Program volatile memories
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