Engine with Transmission, Remove and Install Operation is described for a C 16 XE engine with power steering and AC - proceed analogously for models which are equipped differently.
 Remove, Disconnect Drain AC - see operation "Air Conditioning, Drain" in group "D". Disconnect ground cable from battery. For RHD: remove battery. Disconnect wiring harness plug from mass air flow meter (2, see illus. I). Remove this together with and air cleaner housing (1, see illus. I) and air duct pipe (3, see illus. I). Remove ribbed V-belt - see corresponding operation. Disconnect vacuum hose from brake servo. Release pressure in cooling system by opening closure cap on coolant compensation tank. Remove left coolant hose (2, see illus. II), right coolant hose (3, see illus. II), as well as compensation tank coolant hose from radiator (1, see illus. II). Collect escaping coolant. Remove ignition cable cover. Remove or disconnect all electrical wiring harness connections and vacuum hoses which are attached to engine or transmission. Unclip wiring harness from air intake pipe bracket and set aside. Detach coolant hoses from coolant compensation tank and remove coolant compensation tank. | 
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 Important! Before opening fuel lines: Reduce fuel pressure with Pressure Tester KM-J-34730-91 via testing port - collect escaping fuel in suitable container - observe safety regulations and national legislation.
Remove, Disconnect Detach fuel feed line (1) from fuel distributor pipe and fuel return line (2) from fuel pressure regulator. Detach ground cable from intake manifold (3). Detach Bowden cable from throttle body and set aside. Close off heater hoses with commercially available hose clamps and detach from connection port on the bulkhead (arrows, see illus. III). | 
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Remove, Disconnect For vehicles up to MY '95: unscrew speedometer cable (1) from transmission - for this purpose engage 2nd or 4th gear. For vehicles as of MY '96: detach speedometer cable in engine compartment. For vehicles as of MY '98: detach wiring harness plug from odometer signal sensor. Detach electrical connection cable from alternator. Detach connection terminal 30 and terminal 50 from starter. For vehicles with AC: separate wiring harness plug connection from compressor. Detach and remove front exhaust pipe from exhaust manifold and from catalytic converter connection flange (arrows, see illus. II). | 
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Remove, Disconnect Mark positions of front wheels to wheel hub and remove front wheels. Unscrew clamp bolt from steering knuckle / guide joint and remove guide joint from steering knuckle. Unbolt control arm from body (arrows, see illus. I). For vehicles from MY' 96 with petrol engines and power steering or AC: remove 2 bolts for part engine compartment cover. Detach tension strut bracket from crossmember (see illus. II) and remove with control arm and stabiliser. Detach axle shaft fastening nuts on wheel side. Drive left and right axle shaft out of transmission casing with KM-460-B and remove axle shafts completely (illus. III). Optionally, KM-902 can be used - see corresponding operation in group "E".
 Install, Connect Close off transmission apertures for axle shafts with closure plugs to prevent loss of transmission fluid. | 
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Remove, Disconnect Remove fastening bolt (1) from transmission casing.
Install, Connect Attach bracket for KM-6054 to cylinder block and transmission casing. Attach Base Frame KM-904 with KM-6054 on hydraulic jack and position under 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 (5) upwards until retaining plate bears flush against the transmission. Twist strut bearing (7) upwards until pin bears flush against flattened area (6) of cylinder block. Twist strut bearing (8) upwards until pin bears flush in mount of bracket (9). Twist strut bearing (2) upwards until pin lies flush in mount of flattened area (1). Twist strut bearing (4) upwards until pin bears flush in mount of bracket (3). Lift drive unit slightly. | 
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Remove, Disconnect Release shift tube clamp (1) and detach shift tube from transmission linkage. Detach right engine bracket from engine damping block (2). Detach left engine bracket from engine damping block (3). Detach rear engine bracket from engine damping block (4). Carefully lower engine with transmission approx. 10 cm. | 
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Remove, Disconnect Detach wiring harness plug from AC compressor. Detach refrigerant lines from compressor. Detach power steering pump from power steering pump bracket / compressor, set aside and secure with retaining wire. Move drive unit downwards out of engine compartment with KM-6054.
 Clean Recut thread in front frame side member to remove residual locking compound. | 
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Install, Connect Move drive unit from below into engine compartment with KM-6054. Fit power steering pump to bracket of power steering / compressor pump (1) and to shackle (2, up to MY '95).
 Tighten (Torque) Power steering pump to power steering pump bracket / compressor and to shackle - 20 Nm / 15 lbf. ft. | 
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Install, Connect Connect refrigerant lines to compressor - 40 Nm / 29.5 lbf. ft. Attach wiring harness plug to compressor. |
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Install, Connect Attach engine bracket to engine damping blocks.
Tighten (Torque)
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Left engine bracket to engine damping block |
60 Nm /44 lbf. ft. 1) . |
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Right engine bracket to engine damping block |
60 Nm / 44 lbf. ft. 1) . |
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Rear engine bracket to engine damping block |
60 Nm / 44 lbf. ft. |
1) Bolts must be re-cut before re-use and inserted after being coated with bolt locking compound (red).
Remove, Disconnect Move hydraulic jack downwards and remove Base Frame KM-904 with KM-6054 from hydraulic jack. Remove bracket for KM-6054 from cylinder block and transmission casing.
Install, Connect Attach fastening bolt to transmission casing - tightening torque (M8) 20 Nm / 15 lbf. ft. or (M10) 40 Nm / 30 lbf. ft.
Install, Connect Remove closure caps and press axle shafts into transmission until they engage. Check that axle shaft is firmly seated by pulling at joint (see illus.). Insert axle shaft in front wheel hub. Using new castellated nut and washer, draw loosely into wheel hub (do not fasten yet). | 
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Install, Connect Install control arm together with tension strut and stabiliser (see illus. I). Control arm to front frame (body) - tightening torque 45 Nm / 33 lbf. ft. + 45 ° + 15 ° 1) . Guide joint to steering knuckle - tightening torque 30 Nm / 22 lbf. ft. Secure tension strut bracket to crossmember (front member) (see illus. II) - tightening torque 50 Nm / 37 lbf. ft. + 90 ° + 15 ° 2) . For vehicles from MY' 96 with petrol engines and power steering or AC: attach 2 bolts for part engine compartment cover. Secure axle shaft to front wheel hub. Pretension new castellated nut of axle shaft to 130 Nm / 96 lbf. ft., then release castellated nut again - use KM-468-B (1) (see illus. III) and then turn by a further 20 Nm / 15 lbf. ft. + 90 ° .
Important! If cotter pin hole and castellated nut do not align, unscrew to next hole and secure with pin. Attach front wheels. Wheel to wheel hub - tightening torque 110 Nm / 81 lbf. ft. alternating crosswise. | 
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1) Use new fastening nut(s). 2) Use new fastening bolts.
 Inspect Check transmission fluid level and top up if necessary. Checking aperture left in direction of travel at rear of differential housing (arrow).
 Adjust Attach shift tube to transmission linkage and adjust transmission shift linkage - see operation "Transmission Shift Linkage, Adjust" in group "K". | 
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Install, Connect Install front exhaust pipe with new gasket and new cone. Front exhaust pipe to exhaust manifold - 20 Nm / 15 lbf. ft. Front exhaust pipe to catalytic converter flange - 18 Nm / 13 lbf. ft. Attach electrical connection cable to starter (1 and 2) and alternator. Connect wiring plug connection for AC compressor. | 
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Install, Connect For vehicles up to MY '95: attach speedometer cable to transmission - for this purpose engage 2nd or 4th gear. For vehicles as of MY '96: attach speedometer cable in engine compartment. For vehicles as of MY '98: attach wiring harness plug to odometer signal sensor. Attach heater hoses connection ports on the bulkhead and fasten. Remove hose clamps. Attach Bowden cable to throttle body and adjust if necessary.
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Attach ground cable to intake manifold (arrow). Attach fuel feed line (1) to fuel distributor pipe and fuel return line (2) to fuel pressure regulator. | 
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Install, Connect Reattach or connect any detached or disconnected electrical connection cables and vacuum hoses associated with engine or transmission. Clip wiring harness into air intake pipe bracket. Install coolant compensation tank and attach coolant hoses (see illus.). | 
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Attach ignition cable cover (see illus.) - 8 Nm / 6 lbf. ft. Install ribbed V-belt - see operation "Ribbed V-belt, Remove and Install". | 
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Install, Connect Install air cleaner housing together with air duct pipe and mass air flow meter. Connect wiring harness plug to mass air flow meter (see illus.). Attach left and right coolant hoses as well as compensation tank coolant hose to radiator. Connect ground cable to battery. For vehicles with RHD: install battery. Top up coolant via compensation tank (see illus.) and bleed system - see corresponding operation. Ensure that anti-freeze is adequate to a temperature of -30 ° C / -22 ° F.
Inspect | 
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Allow engine to cool and check coolant level; if necessary, top up coolant. Check all released hose or cable connections for leaks or correct seating. Charge AC - see operation "Air Conditioning, Charge and Evacuate" in group "D". | 
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