Manual Transmission, Remove from Engine and
Install
Remove
2. |
Detach 2x charge air hose
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3. |
Secure radiator at engine transport shackle (2) using retaining
strap (1)
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4. |
Detach 3x coolant hose from radiator
Note: Place collecting
basin underneath.
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Detach coolant delivery hose (3) from radiator
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Unclip from fan housing bracket
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Detach coolant return hose (4) from radiator
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Unclip coolant hose (1) from fan housing
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Detach coolant return hose (2) from coolant pipe
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5. |
Detach compressor wiring harness
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Disconnect compressor wiring harness plug
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Unclip from refrigerant line
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6. |
Detach refrigerant line (1) from condenser
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7. |
Detach engine cooling module
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Unclip 2x vacuum line from radiator
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Remove radiator upward from bracket
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8. |
Detach charge air pipe (5) from turbocharger
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Detach hose (1) from cylinder housing cover
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9. |
Detach oil dipstick guide tube (4)
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10. |
Detach coolant line (3) from compressor
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11. |
Remove coolant pipe assembly (1)
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Unplug wiring harness plug of pre-catalytic converter
temperature sensor (2)
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Detach hose from EGR cooler
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Detach hose from coolant pipe
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12. |
Detach exhaust manifold heat shield (3)
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13. |
Detach exhaust manifold (1)
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Detach with turbocharger and catalytic converter
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Detach EGR metal tube (2)
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Detach oil feed line from engine block
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Unscrew and remove banjo bolt (arrow)
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Detach oil return line (3) from engine block
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Unclip wiring harness of pre-catalytic converter temperature
sensor
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Detach vacuum line from vacuum unit
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Release catalytic converter
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14. |
Attach KM-412-36-2 (1)
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15. |
Detach oil filter housing with heat exchanger (2)
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Place collecting basin underneath.
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Disconnect wiring harness plug for oil pressure switch
(arrow)
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Detach 2x coolant hoses (1)
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16. |
Remove starter
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Release bracket for wiring harness
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Detach 2x wiring harness
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Unscrew 2x bolts (arrows)
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17. |
Detach axle shaft on left and right
Note: 2nd mechanic is
required.
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Place collecting basin underneath.
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Use KM-313 (2) together with KM-902 (1)
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18. |
Remove intermediate shaft (1) with its bracket
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Unscrew 3x bolt (2) of intermediate shaft bracket from engine
block
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Unscrew 3x bolt from end shield
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19. |
Attach KM-412-36-1 (1)
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20. |
Attach adapter plate KM-883-2
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3x at engine transport shackle
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Suspend from workshop crane
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21. |
Attach drive unit to ropes at KM-883-2
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22. |
Release rear reaction member
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Detach wiring harness bracket from reaction member
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23. |
Release front reaction member
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24. |
Lift drive unit
Note: 2nd mechanic is
required.
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25. |
Attach drive unit to KM-412-A
Note: 2nd mechanic is
required
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26. |
Detach transmission wiring harness
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Detach reversing lamp wiring harness plug
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27. |
Detach charge air pipe (2) from throttle valve module
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28. |
Attach transmission to ropes
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30. |
Remove gearbox
Note: 2nd mechanic is
required
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Install
31. |
Position transmission
Note: 2nd mechanic is
required.
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Screw in bolt
Note: Do not tighten
bolt yet
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32. |
Attach transmission to cylinder block
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Tighten 2x bolt M12 (1)
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Tighten 2x bolt M12 60 Nm
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33. |
Attach transmission to oil pan
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Tighten 2x bolt M10 40 Nm
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34. |
Detach transmission from ropes
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35. |
Attach charge air pipe
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36. |
Attach transmission wiring harness
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Fasten reversing lamp wiring harness plug
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37. |
Suspend drive unit with KM-883-2 from
workshop crane
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38. |
Detach drive unit from KM-412-A
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39. |
Place drive unit on KM-6001-A
Note: Note contact
points, 2nd mechanic is required.
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Attach rear reaction member
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Attach front reaction member
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40. |
Secure front reaction member
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Tighten screwed joint 55 Nm
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41. |
Fasten rear reaction member to transmission
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42. |
Untie ropes from drive unit
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Remove from workshop crane
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43. |
Detach adapter plate KM-883-2
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Release transport catch
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45. |
Attach oil filter housing with heat exchanger
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Connect oil pressure switch wiring harness plug
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46. |
Install starter
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Tighten stud bolt 25 Nm
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Attach 2x wiring harness
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Fasten bracket for wiring harness
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48. |
Cleaning work
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Clean sealing surface
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Exhaust manifold, cylinder head
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49. |
Attach exhaust manifold with turbocharger and catalytic
converter
Note: Fill 0.4 ml clean
engine oil into the aperture of the oil feed line
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Tighten 8x new nut 25 Nm
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Attach oil feed line
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Tighten banjo bolt 15 Nm
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Clip in wiring harness of pre-catalytic converter temperature
sensor
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Attach vacuum line to vacuum unit
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Fasten catalytic converter
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Tighten 2x bolts
Note: Clean thread
before re-using and insert bolt with locking compound (red). The
maximum installation time including torque check is 10 minutes.
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50. |
Attach exhaust manifold heat shield
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51. |
Cleaning work
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Clean sealing surfaces.
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Coolant pipe, cylinder head
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52. |
Attach coolant pipe assembly
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Tighten toothed belt cover bolt to coolant flange
Note: Clean thread
before re-using and insert bolt with locking compound (red). The
maximum installation time including torque check is 10 minutes.
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Attach hose to EGR cooler
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Attach hose to coolant pipe
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Plug in wiring harness plug of pre-catalytic converter
temperature sensor
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53. |
Attach refrigerant line to compressor
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54. |
Attach dipstick guide tube
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55. |
Attach charge air pipe to turbocharger
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Attach hose to cylinder head cover
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56. |
Attach intermediate shaft with its bracket
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Tigthen 3x intermediate shaft bracket bolt to engine block
55 Nm
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Tighten 3x bolt to end shield 18
Nm
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57. |
Replace 2x axle shaft retaining ring on left and right
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Important: Retaining ring must
engage audibly.
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58. |
Attach axle shaft on left and right
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59. |
Attach engine cooling module
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Insert radiator into bracket from above
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Secure radiator at engine transport shackle using retaining
strap
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Clip in 2x vacuum line to radiator
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60. |
Attach refrigerant line to condenser
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61. |
Attach compressor wiring harness
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Fix wiring harness plug
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Clip in at refrigerant line
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62. |
Attach 3x coolant hose to radiator
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Attach coolant delivery hose to radiator
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Clip into fan housing bracket
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Attach coolant return hose to radiator
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Clip coolant hose into fan housing
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Attach coolant return hose to coolant pipe
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63. |
Attach 2x charge air hose
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64. |
Remove retaining strap from radiator
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65. |
Check transmission fluid level and correct if necessary
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