Engine, Remove and Install
2. |
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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3. |
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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4. |
Empty climate control system
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5. |
Remove lower driver's side cover
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Release 2x retaining clips
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6. |
Detach steering column intermediate shaft
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Set steering wheel in straight ahead position, remove ignition
key and engage steering lock
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7. |
Remove battery
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Detach positive connection from positive terminal
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Remove battery bracket (2)
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8. |
Disconnect charge pressure sensor wiring harness plug
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9. |
Disconnect upper cooling module wiring harness
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Disconnect wiring harness connector.
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Unclip relay from bracket
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10. |
Remove battery support (2)
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Detach wiring harness from battery support
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11. |
Remove air cleaner housing with mass air flow sensor
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Disconnect air mass flow meter wiring harness plug
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Detach air intake hose from air intake pipe
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Unscrew bolt
Note: The wiring
harness plug cannot be disconnected without first removing the mass
air flow sensor from the air cleaner housing
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12. |
Detach brake servo vacuum line from intake manifold
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Disconnect quick-release fitting
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Unclip vacuum line from bracket
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13. |
Remove air intake pipe
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Remove engine vent hose from cylinder head cover
Note: Seal air intake
pipe to turbocharger
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14. |
Place collecting basin underneath.
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15. |
Relieve fuel pressure using KM-J-34730-91 at test connection
Note: Collect exiting
fuel in a suitable container - observe safety regulations and
national legislation.
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16. |
Detach fuel supply line (2)
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Undo quick-release fitting with KM-796-A
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17. |
Detach fuel return line (1)
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Undo quick-release fitting with KM-796-A
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18. |
Detach venting line of tank vent valve
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Undo quick-release fitting with KM-796-A
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19. |
Disconnect fuel vapour separator line
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Undo quick-release fitting (1)
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20. |
Detach brake servo vacuum line from intake manifold
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Disconnect quick-release fitting (2)
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22. |
Raise vehicle by half its height
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23. |
Remove 2x front wheels
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24. |
Remove front panelling (3)
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Remove 5x body-bound rivets (2)
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25. |
Place collecting basin underneath.
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26. |
Detach high-pressure headlamp cleaning system hose from
reservoir
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Disconnect quick-release fitting
Note: Escaping
fluid
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27. |
Remove front panelling
Note: Use a second
person
Note: Push front
panelling upwards at side and pull out of bracket
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Detach front panelling from bracket
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Unclip outside temperature sensor
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28. |
Remove engine splash guard (right-hand)
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Remove 2x body-bound rivet
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29. |
Detach 2x axle shafts from wheel hub
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Unscrew 2x nuts (2) from axle shaft
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Counterhold with KM-6610 (1) at front
wheel hub
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30. |
Undo tie rod end (6) from steering knuckle (5)
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Attach CH-47658 (1)
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Position CH-47658 (1) with suitable
sleeve (4)
Note: In order to
centre CH-47658 , CH-47658 must be used with the appropriate socket
wrench groove (3).
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Fasten CH-47658 (1) to hexagonal
section (2)
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Unscrew tie rod end nut
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31. |
Press tie rod out of steering knuckle using KM-161-B (1) in conjunction with hook KM-161-2
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32. |
Detach 2x swing arms (1) from spring strut support tube
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Use open-ended wrench to hold against the flat surfaces
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33. |
Detach guide joint from steering knuckle
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Detach 2x screw connections
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Expand steering knuckle with KM-915
(2)
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Pull guide joint out of steering knuckle
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34. |
Press axle shaft out of wheel hub
Note: Do not pull the
steering knuckle outwards when doing so. Use a wheel hub puller if
necessary.
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35. |
Raise vehicle by half its height
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36. |
Release left wheel housing inner panelling
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Remove 3x body-bound rivets
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37. |
Detach cooling module wiring harness (1)
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Disconnect wiring harness connector.
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38. |
Place collecting basin underneath.
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39. |
Drain coolant
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Unscrew coolant drain bolt
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Screw in coolant drain bolt
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40. |
Detach catalytic converter control's oxygen sensor wiring
harness
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Disconnect wiring harness connector.
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41. |
Remove front exhaust pipe
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Detach front exhaust pipe (1) from catalytic converter
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Detach front exhaust pipe from middle silencer
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42. |
Remove right drive shaft from intermediate shaft
Note: Drive out with
soft metal drift
Note: Oil flows out.
Place collecting pan underneath and seal the openings with a
plug.
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43. |
Carefully place the axle shaft down
Note: Do not lay it on
the boots.
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44. |
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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45. |
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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46. |
Lower vehicle by its full height
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47. |
Remove coolant expansion tank (1)
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Pull out of bracket in direction of arrow
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48. |
Detach 2x shift cables
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49. |
Disconnect the pressure line for central disengagement at the
clutch housing
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Release clamp with screwdriver in direction of arrow and
remove
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Lock retaining clamp
Note: Seal of line
ends
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50. |
Disconnect steering wiring harness
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Remove fuse carrier cover
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Detach positive cable from fuse carrier
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Disconnect wiring harness connector.
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Expose wiring harness
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Remove 2x from wiring harness bracket
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51. |
Disconnect wiring harness plug of reversing lights
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52. |
Disconnect wiring harness plug (1)
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Release retainer in direction of arrow
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53. |
Disconnect engine wiring harness
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Unclip oxygen sensor wiring harness plug from bracket
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Disconnect wiring harness connector.
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Disconnect wiring harness plug of engine control unit
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Unclip 2x retaining clips
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54. |
Detach coolant hoses (1) from heater core
Note: Mark assignment
using coloured markings
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Place collecting basin underneath.
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Release 2x quick-release fittings in direction of arrow
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55. |
Disconnect refrigerant line (low pressure side)
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56. |
Detach refrigerant line from condenser
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57. |
Detach right engine damping block from engine damping block
bracket
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58. |
Detach left engine damping block from engine damping block
bracket
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59. |
Raise vehicle by its full height
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60. |
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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61. |
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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62. |
Move out front axle body
Note: Use a second
person
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Important: Ensure that no
attached parts are damaged
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63. |
Move front axle body back in
Note: Use a second
person
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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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64. |
Fit front axle body
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Tighten 6x new bolt 90 Nm + 45° +
15°
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65. |
Remove KM-904 with KM-6390
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Detach KM-904 and KM-6100 from hydraulic jack
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66. |
Lower vehicle by its full height
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67. |
Attach right engine damping block to engine damping block
adapter
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68. |
Attach left engine damping block to engine damping block
adapter
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69. |
Attach refrigerant line to condenser
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70. |
Connect refrigerant line (low pressure side)
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Important: It is imperative to
adhere to the following assembly order
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71. |
Attach cooling 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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72. |
Connect engine wiring harness
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Connect wiring harness plug of engine control unit
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Clip in 2x retaining clips
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Fix wiring harness plug
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Clip oxygen sensor wiring harness plug to bracket
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73. |
Fix wiring harness plug
Note: Front wiring
harness plug to fuse carrier
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74. |
Connect wiring harness plug, reverse gear
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75. |
Connect steering wiring harness
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Clip in 2x wiring harness brackets
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Attach positive cable to fuse carrier
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Fix wiring harness plug
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Install fuse carrier cover
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76. |
Connect central release pressure line at clutch housing
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Connect quick release fitting
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77. |
Attach 2x shift cables
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78. |
Raise vehicle by its full height
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81. |
Install right drive shaft in intermediate shaft
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82. |
Install front exhaust pipe
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Attach front exhaust pipe with new gasket to catalytic
converter 20 Nm
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Attach front exhaust pipe to middle silencer
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83. |
Attach catalytic converter control oxygen sensor wiring
harness
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Fix wiring harness plug
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84. |
Lower vehicle by half its height
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85. |
Attach cooling module wiring harness
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Fix wiring harness plug
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86. |
Fit left wheel housing inner panelling
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Install 3x body-bound rivets
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87. |
Install 2x axle shafts into wheel hub
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Tighten 2x new nuts
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Counterhold at wheel hub with KM-468-B
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88. |
Attach 2x guide joints to steering knuckle
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Tighten 2x new screwed joint 100
Nm
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89. |
Attach 2x swing arms to spring strut support tube
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Tighten 2x new nut 65 Nm
Note: Use spanner to
counterhold against flat surface
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90. |
Attach 2x tie rods to steering knuckle
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Tighten 2x new nut 50 Nm
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91. |
Install right engine splash guard
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Install 2x body-bound rivets
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92. |
Insert front panelling
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Second mechanic
Note: Slide side front
panelling into bracket
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Attach front panelling to bracket
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Clip in outside temperature sensor
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93. |
Fit front panelling
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Install 5x body-bound rivets
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94. |
Attach high-pressure headlamp cleaning hose to reservoir
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Connect quick release fitting
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96. |
Lower vehicle by half its height
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97. |
Fasten 2x front wheels 110 Nm
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98. |
Install vacuum reservoir vacuum line to turbocharger
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99. |
Attach venting line of tank vent valve
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Connect quick release fitting
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100. |
Attach fuel return line to fuel rail
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101. |
Attach fuel supply line to fuel rail
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102. |
Install air intake pipe.
Note: Install air
intake pipe connection to turbocharger
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Attach engine vent hose to cylinder head cover
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Fasten clamp; tighten bolt
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103. |
Attach brake servo vacuum line to intake manifold
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Connect quick release fitting
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Clip vacuum line into bracket
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104. |
Install air cleaner housing with mass air flow sensor
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Insert the air cleaner housing
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Attach air intake hose to air intake pipe
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Connect mass air flow meter wiring harness plug
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105. |
Attach brake bleeder unit to bleeder valve
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Remove valve cap from connecting piece's bleeder valve
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Attach MKM-6174-1 to bleeder
valve
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106. |
Attach brake bleeder unit to brake fluid reservoir
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Attach brake bleeder unit adapter to brake fluid reservoir
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Attach MKM-6174-2 to brake bleeder
unit adapter
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107. |
Bleed clutch actuation
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Activate brake bleeder unit
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Close bleeder valve hand-tight
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Deactivate brake bleeder unit
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108. |
Detach brake bleeder unit from brake fluid reservoir
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Detach brake bleeder unit adapter from brake fluid
reservoir
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Fit brake fluid reservoir cover
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109. |
Bleed transmission housing pressure line for central
disengagement
Note: Second
mechanic
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110. |
Detach brake bleeder unit from bleeder valve
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111. |
Check and correct brake fluid level
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112. |
Install battery holder
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Attach wiring harness to battery support
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113. |
Insert coolant expansion tank in bracket
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114. |
Connect upper cooling module wiring harness
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Fix wiring harness plug
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Clip relay into bracket
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115. |
Connect charge pressure sensor wiring harness plug
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116. |
Install battery
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Install battery bracket
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Attach positive connection to positive terminal
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117. |
Attach positive cable to positive terminal
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118. |
Connect battery
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Attach ground connection to ground terminal
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119. |
Attach earth cable to earth terminal
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120. |
Fill with coolant and correct coolant level
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121. |
Top up climate control system
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123. |
Attach steering intermediate shaft
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Coat bolts with bolt locking compound.
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124. |
Install lower driver's side cover
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Lock 2x retaining clips
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125. |
Programme transient memory
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