Engine with Transmission, Remove and Install
 Remove, Disconnect Disconnect ground cable from battery. RHD vehicles: remove battery. Remove air cleaner housing with air intake hose. | 
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Depressurise cooling system by opening closure cap on coolant compensation tank. Unscrew coolant drain bolt from cylinder block (arrow). Collect escaping coolant. | 
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Remove, Disconnect Disconnect vacuum hose from brake servo (1). RHD vehicles: Unscrew vacuum line from vacuum pump and toothed belt panelling and lay aside. Disconnect coolant hoses from compensation tank. Remove compensation tank (2). Disconnect heating hoses from ports on bulkhead (3) | 
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Remove, Disconnect Remove upper coolant hose completely (1). Unbolt speedometer cable. Detach wiring plug connection of engine wiring harness. Disconnect wiring plug connections from fuel filter heating. Unbolt fuel feed line and return line from filter (see illus. III). Remove safety tank with fuel filter. | 
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Remove, Disconnect Remove clip from clutch cable and detach cable (see illus. I). Remove wiring plug connection from reversing lamps switch. Detach accelerator cable. Remove retainer from ball socket and press off ball socket (see illus. II). Detach cable from bracket. Disconnect wiring plug connection from oil pressure switch and temperature sensor (arrow, see illus. III). Unbolt connecting cable from contact rail of sheathed glow plugs. | 
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Remove, Disconnect Disconnect wiring plug connections from thermoswitch and fan motor (see illus. I). Detach wiring harness from fastening on intake manifold (see illus. II). Vehicles with power steering: Release tension in V-belt and remove. Unscrew power steering pump from bracket at cylinder block (arrows, see illus. III).
 Important! System remains closed. | 
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Remove, Disconnect Disconnect wiring plug connection from alternator (see illus. I). Remove lower coolant hose completely (see illus. II). Loosen shift tube clamp and remove shift tube from linkage on transmission (see illus. III). | 
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Remove, Disconnect Disconnect starter (see illus. I). Unbolt ground cable from cylinder block. Pull wiring plug connection for solenoid cutoff valve from bracket on injection pump and disconnect (see illus. II). Unbolt front exhaust pipe from exhaust manifold (see illus. III) or from turbocharger connection (15 DT and X 15 DT) and from bracket on cylinder block (see illus. III). Detach exhaust system from rubber retainers and swing aside. | 
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Remove, Disconnect Unbolt clamp bolts, steering knuckles/guide joints and remove guide joints from steering knuckles (see illus. I). Unbolt control arm from body (see illus. I). Loosen tension strut bracket from crossmember and remove with control arm and stabiliser (15 DT, X 15 DT, 17 D, X 17 D) (see illus. II). Drive left axle shaft with KM-460-2A, right axle shaft with KM-460-1 (or use KM-902) out of transmission casing and tie up axle shafts (see illus. III) - see operation "Axle Shaft, Remove" in group "E". To prevent loss of transmission fluid, close off transmission openings for axle shafts with plugs. | 
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Remove, Disconnect Remove cover plate (1) for flywheel. Remove exhaust pipe bracket (2) from cylinder block.
 Install, Connect Attach bracket for KM-6054 to cylinder block. Attach Base Frame KM-904 with Engine Mount KM-6054 on hydraulic jack and position under the drive unit. Notice: To ensure correct alignment of the drive unit after the engine damping blocks have been released, the drive unit must be aligned with the body using KM-6054. The attachment of KM-6054 is described below. | 
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Install, Connect Twist strut bearing retaining plate (4) upwards until retaining plate bears flush against the transmission. Twist strut bearing (6) upwards until pin bears flush against the flattened area (5) of the cylinder block. Twist strut bearing (7) upwards until pin lies flush in mount of bracket (8). Twist strut bearing (2) upwards until pin lies flush in mount of flattened area (1). Twist strut bearing (3) upwards until pin lies flush in mount of flattened area of cylinder block on transmission side. | 
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Remove, Disconnect Slightly lift drive unit with KM-6054 and unscrew front right, front left and rear engine damping blocks from body (see illus.). Remove engine with transmission downwards out of engine compartment.
 Clean To remove locking compound residue, recut thread in front frame side member for fastening engine damping blocks.
Install, Connect | 
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Insert coolant drain bolt with surface sealant (green) into cylinder block and tighten. Insert engine with transmission into engine compartment from below. | 
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Install, Connect Attach right and left engine damping blocks to side member - tightening torque 65 Nm / 48 lbf. ft. 1)
. Attach rear engine damping block to underbody - tightening torque 65 Nm / 48 lbf. ft. Move hydraulic jack downwards and remove Base Frame KM-904 and KM-6054 from hydraulic jack. Remove bracket for KM-6054 from cylinder block and attach exhaust pipe bracket to cylinder block - tightening torque 25 Nm / 18 lbf. ft. Install cover plate for flywheel - tightening torque 7 Nm / 5 lbf. ft. Press both axle shafts into transmission housing until they engage.
 Inspect |
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Check that axle shafts are firmly seated by pulling on joint. | 
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1) Bolt must be re-cut before re-use and inserted with bolt locking compound (red).
Install, Connect Insert guide joints into steering knuckle. Install control arms and tie struts with stabilisers.
 Tighten (Torque)
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Guide joint to steering knuckle |
- 30 Nm / 22 lbf. ft 1) |
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Control arm to body |
- 60 Nm / 44 lbf. ft |
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Tension strut bracket to crossmember |
- 50 Nm / 37 lbf. ft. + 90 ° + 15 ° 2) 3) |
1) Use new fastening nut(s). 2) with screw locking compound (red). 3) Use new bolts.
Install, Connect | 
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Connect solenoid cutoff valve wiring plug connection and press into bracket on injection pump. Connect starter cable. Attach exhaust system to rubber retainers. Bolt front exhaust pipe with new gasket to exhaust manifold, or turbocharger connection (15 DT) and to bracket on cylinder block.
Tighten (Torque) Exhaust pipe to exhaust manifold/turbocharger connection - 70 Nm / 52 lbf. ft. | 
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Install, Connect Push shift tube onto linkage (see illus. I).
 Adjust Adjust shift linkage - see operation "Transmission Shift Linkage, Adjust" in group K.
Install, Connect Install lower coolant hose. Connect alternator wiring plug connection (see illus. II). Screw power steering pump onto bracket (see illus. III). Install V-belt and tension - see operation "V-belt Tension, Check and Adjust".
Tighten (Torque) Power steering pump to bracket - 27 Nm / 20 lbf. ft. | 
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Install, Connect Attach accelerator cable. Attach cable to bracket, press ball socket onto ball head and secure (see illus. I). Fasten wiring harness to bracket on intake manifold with cable clamps. Connect wiring plug connections for thermoswitch and fan motor.
Install, Connect Connect heating hoses to ports on bulkhead. Install upper coolant hose.
Install, Connect Connect wiring plug connection to oil pressure switch and temperature sensor. Screw on speedometer cable. Attach clutch cable and clamp (see illus. II). Wiring harness plug to reversing lamp switch. Fasten coolant hoses at compensation tank and install compensation tank. | 
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Install, Connect Connect engine wiring harness plug connection. Fasten connection cable for sheathed glow plugs contact rail. | 
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Install safety tank with fuel filter. Connect fuel feed line and return line with new seal rings to fuel filter. Connect wiring plug connections to filter heating.
Tighten (Torque) Safety tank to side member - 35 Nm / 26 lbf. ft. | 
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Install, Connect Connect vacuum hose to brake servo. RHD vehicles: Connect vacuum line to vacuum pump and fasten to toothed belt panelling.
Tighten (Torque) Vacuum line to toothed belt panelling - 10 Nm / 7 lbf. ft. | 
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Install, Connect Install air intake hose and air cleaner housing. Connect ground cable to battery. RHD vehicles: Install battery. Top up coolant via compensation tank. Ensure that anti-freeze is adequate down to - 30 ° C/- 22 ° F. Cooling system bleeds automatically during engine warm-up phase.
Inspect Allow engine to cool and if necessary top up coolant to mark "Kalt" (cold) in compensation tank. | 
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