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Engine, Remove and Install (X 12 XE, Z 12 XE)
Note: The operation
"Engine, Remove and Install" is described for an X 12 XE engine
with, AC and LHD. Proceed analogously for models which are equipped
differently.
Cable ties detached for removal of the engine must be reattached
at the same location on installation.
Caution
For vehicles with airbag: Turn steering to straight ahead
position, remove ignition key and engage steering lock.
 Remove
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Remove clamping bolt (1) on steering column intermediate spindle
(interior).
Drain air conditioning – see operation "Air Conditioning,
Drain" in group "D".
Open coolant drain bolt – collect escaping coolant.
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Disconnect earth cable (3) from earth connection and disconnect
earth connection (4) from battery.
Disconnect positive lead (2) from positive terminal and
disconnect positive terminal (1) from battery.
Remove battery.
Detach battery support (5) from body.
Remove air cleaner housing with hot film mass air flow meter and
air intake cover - see illustration "Air Ducts X 12 XE" or "Air
Ducts Z 12 XE" or "Air Ducts Z 14 XEP".
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Detach accelerator Bowden cable (1) from curved disc and
bracket.
Note: It must be
ensured that the valve support is not damaged when disconnecting
the tank vent valve hose from the valve body. Damaged valves must
be replaced.
Caution
Damaged valve supports can cause a vehicle fire as a result of
leaks.
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Remove
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Detach tank vent valve hose at separation point provided.
Detach brake servo vacuum line (1) from intake manifold.
Reduce fuel pressure with KM-J-34730-91 via testing port –
collect escaping fuel in suitable container – observe safety
regulations and national legislation.
Detach fuel feed line (2) from fuel distributor pipe.
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Disconnect or detach following wiring harness plugs.
- Engine control unit wiring harness plug (1)
- Multiplug (6)
- Multiplug (twist connection) (5)
- Oxygen sensor (7)
Disconnect steering cable bunch and put out of way:
- Withdraw fuse carrier (2) from bracket
- Disconnect wiring harness plug (4)
- Detach earth cable (3) from body
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Release coolant hose (1) in direction of arrow and detach from
heater core.
Detach coolant hose (2) from throttle body.
Detach coolant hose (4) from compensation tank.
Detach coolant hose (3) from radiator.
Release pressure line with connector (5) from pressure line for
central release mechanism on clutch housing – detach clutch
pressure line for this operation. Release clamp (6) with
screwdriver – then bend clamp slightly together and re-insert
in connector.
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Front Wheels, Remove.
Remove front panelling – see operation "Front Panelling,
Remove and Install" in group "A".
Detach swing arm (1) on both sides from spring strut support
tube – counterhold with open-ended spanner at the two
flattened surfaces.
Withdraw axle shafts on both sides from wheel hub (do not remove
from transmission) – see operation "Axle Shaft, Remove and
Install" in group "E".
Remove lower right engine splash guard.
Unlock wiring harness plug (2) in direction of arrow and detach
from cooling module control unit.
Disconnect earth cable (3) from body.
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Remove front exhaust pipe with catalytic converter and centre
muffler.
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Release clamp (1) from shift rod and disconnect shift guide from
shift rod.
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Note: The drive unit
must be aligned to the front axle body using KM-6173 and KM-6001-A
in order to ensure correct alignment of the drive unit after
releasing the fastening bolts for the right and left engine damping
blocks. The attachment of KM-6173 and KM-6001-A is described in the
following.
Install
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Attach KM-6173 (3) to front axle body – screw up support
bearing (2) until pin is seated flush in mount (1) on cylinder
block.
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Release fastening bolts (arrows) for adjustment rails on
KM-6001-A (1).
Insert KM-6001-A as illustrated – pins (2) and (5) must
sit in guide holes of front axle body.
Tighten fastening bolts for adjustment rails.
Screw up front support bearing (4) and rear support bearing (3)
until contact is made with guide pins of front engine damping block
and rear engine damping block bracket – the guide pins must
seat free from play in the support bearings.
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For version with air conditioning:
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Remove fastening bolt (1) and disconnect refrigerant line.
Remove fastening bolt (2) and detach refrigerant line from
receiver-dryer.
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Detach right engine damping block bracket (1) and left engine
damping block bracket (2) from engine damping block support.
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Install
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Position KM-904 with KM-6000 onto hydraulic jack and place under
front axle body free of play (use hydraulic jack which can be
lowered to at least 100 cm).
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Caution
Dismantling of front axle body using an impulse or impact
screwdriver is not permissible. Note dissimilar bolt lengths.
Note: For a clearer
representation, the illustration shows the front axle body without
hydraulic jack and KM-6000.
Install
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Remove six rear fastening bolts (4) on left and right. Remove
front fastening bolts on right (1) and left (3). Remove centre
fastening bolts (2).
Carefully lower front axle body with entire drive unit, steering
gear and radiator – thereby ensuring that no attaching parts
are damaged.
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Caution
Ensure the threads of the captive nuts move freely before
installing front axle body with drive unit, steering gear and
radiator, replace captive nuts if necessary.
Install
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Carefully guide front axle body with entire drive unit, steering
gear and radiator into engine compartment and position free of play
on chassis – thereby ensuring that no attaching parts are
damaged.
Attach front axle body to vehicle underbody with new fastening
bolts (1- 4) – tightening torque 90 Nm / 66 lbf. ft. +
45° + 15°.
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Caution
Installing the front axle body using an impulse or impact
screwdriver is not permissible. Note dissimilar bolt lengths and
washers.
Install
Attach right engine damping block bracket to engine damping
block support – tightening torque 55 Nm / 41 lbf. ft.
Attach left engine damping block bracket to engine damping block
support – tightening torque 55 Nm / 41 lbf. ft.
For version with air conditioning:
Connect refrigerant line – tightening torque 20 Nm / 15
lbf. ft.
Attach refrigerant line to receiver-dryer – tightening
torque 20 Nm / 15 lbf. ft.
Remove
Remove KM-6001-A and KM-6173.
Install
Attach shift guide using clamp to shift rod – it is only
tightened after the transmission shift linkage is adjusted.
Install front exhaust pipe with catalytic converter and centre
silencer.
Connect earth cable for cooling module control unit to body.
Attach wiring harness plugs to cooling module control unit and
lock.
Install lower right engine splash guard.
Install axle shafts – see operation "Axle Shaft, 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 – see operation "Front Panelling,
Remove and Install" in group "A".
Attach front wheels – tightening torque – 110 Nm /
81 lbf. ft.
Attach pressure connection for hydraulic clutch actuator to
manual transmission.
Attach coolant hoses – ensure correct seating.
Attach or connect wiring connections for engine and steering
– note cable routing.
Attach fuel feed lines to fuel distributor pipe –
tightening torque 15 Nm / 11 lbf. ft.
Connect brake servo vacuum line to intake manifold.
Connect tank vent valve hose.
Attach accelerator Bowden cable to curved disc.
Install air cleaner housing with hot film mass air flow meter
and air intake cover - see illustration "Air Ducts X 12 XE" or "Air
Ducts Z 12 XE" or "Air Ducts Z 14 XEP".
Attach battery support to body- tightening torque 15 Nm / 11
lbf. ft. Install battery and fasten to battery support. Connect
battery electrically.
For version with air conditioning: Evacuate and charge air
conditioning – see operation "Air Conditioning, Evacuate and
Charge" in group "D".
Bleed hydraulic clutch actuation – see operation
"Hydraulic Clutch Actuation, Bleed (F13/F17/F18/F23)" in group
"K".
 Adjust
Adjust shift mechanism – see operation "Transmission Shift
Linkage, Adjust (F13/F17/F18)" in group "K".
Inspect
Charge cooling system – see operations "Cooling System,
Charge and Bleed" and "Cooling System, Check for Leaks".
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