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Engine, Remove and Install
Note: The operation
"Engine, Remove and Install" is described for an X 20 SE engine.
Proceed analogously for other engine versions.
Cable ties which are released or detached for removing the engine
must be re-installed in the same position during installation.
Turn steering wheel to straight-ahead position, remove ignition key
and allow steering lock to engage.
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 Remove
In vehicles with AC: Drain AC – see operation "AC, Drain"
in group "D".
Disconnect ground terminal from battery and detach ground cable
(1) from ground terminal.
Detach positive cable (2) from positive terminal and disconnect
positive terminal from battery.
Open relay frame cover.
Remove engine control unit (3) – see operation "Engine
Control Unit, Remove and Install".
Remove relays (4) and (5) with sockets out of relay frame.
Remove engine wiring harness with relay frame rubber
grommet.
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Disconnect engine wiring harness at multiplug (twist lock) and
lay engine wiring harness aside on engine.
Open coolant drain bolt on radiator – collect coolant.
Close coolant drain bolt.
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Remove upper coolant hose (1) from thermostat housing.
Detach high pressure line (2) from power steering pump –
collect hydraulic fluid.
Detach intake line (3) from power steering fluid reservoir.
Detach brake servo vacuum line from brake servo.
For vehicles with air conditioning: Push back rubber cover from
refrigerant lines and disconnect refrigerant lines at separation
point with KM-917.
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For version with manual transmission: Top up brake fluid
reservoir completely and close off with dummy plug.
Open retaining strap (2) for connecting piece on bulkhead.
Detach retaining clip (1) and disconnect clutch actuation pressure
line.
Reinsert retaining clip.
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Remove
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Remove accelerator Bowden cable from Bowden cable bracket.
If present: Detach cruise control Bowden cable with bracket (1)
from intake manifold. Detach vacuum hose (2) from intake manifold
– remove Bowden cable bracket.
Caution
Fuel escapes. Observe safety regulations and national
regulations. Depressurise fuel using Fuel Pressure Gauge
KM-J-34730-91 via test connection – collect escaping fuel in
suitable container.
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Remove
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Disconnect wiring harness plug from intake air temperature
sensor (3) and hot film mass air flowmeter (2).
Detach air intake hose (1) from throttle body and air cleaner
housing.
Detach coolant hose (4) from throttle body.
Separate tank vent valve vacuum hose below coolant compensation
tank.
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Remove front wheels.
Remove fastening nuts for tie rods from steering knuckle. Detach
tie rods from steering knuckle with KM-507-C.
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Remove fastening nut on steering arm (1).
Push out steering arm (2) using KM-146-01
Remove fastening nuts (4) from idler bracket (3) and remove
entire steering linkage.
Detach link rod fastening bolts on both sides from stabiliser
– counterhold at the flattened surfaces with open-ended
wrench.
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Detach fastening nuts (1) and remove fastening bolts.
Pull guide joints (2) downwards out of steering knuckle.
Disconnect wiring harness plug for oxygen sensor. Remove front
exhaust pipe with catalytic converter.
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Disconnect transmission fluid lines (1) and connect to each
other – collect escaping transmission fluid.
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Detach selector lever linkage (2).
Remove propshaft (1) from transmission.
For version with manual transmission: Remove propshaft –
see operation "Propshaft, Remove and Install or Replace" in group
"F".
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For version with manual transmission: Remove 4 clips (arrows)
from cover on shift outrigger.
Push cover forwards.
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Detach retainer (arrow) from pin.
Pull pin out from shift rod and fork.
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For version with manual transmission: Remove fastening bolts
(arrow) from shift outrigger.
Disconnect AC compressor wiring harness plug (1).
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Install Base Frame KM-904 with Centring Mount KM-6190 on
hydraulic jack and position without play under front axle body
– ensure that the centring pins (2) and (4) sit in the
corresponding mounts of the front axle body (use hydraulic jack
which can be lowered to at least 100 cm).
Caution
Removal of the front axle body with an impulse or impact
screwdriver is not permissible. Note various lengths of bolts.
Note: Before removing
the engine, the split pins of the centring pins (1) and (3) must be
pulled out so that the centring pins cannot engage in the
corresponding bores.
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Unscrew transmission holder from underbody.
Remove front fastening bolts (1), centre fastening bolts (2) and
rear fastening bolts (3).
Carefully lower front axle body with engine and transmission
– ensure that no attaching parts are damaged.
Lower hydraulic jack completely.
Caution
Ensure the threads of the captive nuts move freely before
installing front axle body and transmission, replace captive nuts
if necessary.
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Install
Carefully guide front axle body with engine and transmission
into engine compartment and lift until the drive unit is positioned
free of play on the chassis – ensure that the centring pins
of KM-6190 are seated in the corresponding mounts and no attaching
parts are damaged.
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Note: Before
installing the engine, the centring pins (1) and (3) must be pushed
up and secured with the corresponding split pins.
When moving in the engine, ensure that centring pins (1), (2), (3)
and (4) engage in the corresponding mounts of the front axle body /
underbody.
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Install
Insert new fastening bolts for front axle body to front member
and side member.
Tighten fastening bolts for front of front axle body (1) to
front member – tightening torque 65 Nm / 48 lbf. ft. +
30° + 15°.
Tighten fastening bolts (2) for centre of front axle body to
side member – tightening torque 150 Nm / 111 lbf. ft. +
30° + 15°
Tighten fastening bolts (3) for rear of front axle body to side
member – tightening torque 130 Nm / 96 lbf. ft. + 30° +
15°
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Attach transmission holder to underbody – tightening
torque 45 Nm / 33 lbf. ft. 1)
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Lower hydraulic jack with KM-904 and KM-6190 and remove.
Connect wiring harness plug for air conditioning compressor.
For versions with manual transmission: Attach shift outrigger.
Attach shift fork to shift rod. Secure shift outrigger cover.
Attach propshaft – see operation "Propshaft, Remove and
Install" in group "F".
Attach propshaft to transmission – tightening torque 95 Nm
/ 70 lbf. ft.
Connect selector lever rod.
Connect transmission fluid lines.
Connect guide joints to steering knuckle – tightening
torque 100 Nm / 74 lbf. ft.
Attach link rods to stabiliser with new fastening nut –
tightening torque 65 Nm / 48 lbf. ft.
Attach idler bracket to body – tightening torque 55 Nm /
41 lbf. ft. +75° +15° 1)
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Attach steering arm to steering shaft with new fastening nut
– tightening torque 160 Nm / 118 lbf. ft.
Connect tie rods to steering knuckle with new fastening nuts
– tightening torque 60 Nm / 44 lbf. ft.
Install front exhaust pipe with catalytic converter –
tightening torque 25 Nm / 18 lbf. ft. 2) – Use
new gasket.
Attach front wheel – tightening torque 110 Nm / 81 lbf.
ft.
Attach lower engine compartment cover.
Connect tank vent valve vacuum hose.
Attach coolant hose to throttle body.
Attach air intake hose to throttle body and air cleaner housing
– tightening torque 3.5 Nm / 2.6 lbf. ft.
Connect wiring harness plug for outside air temperature sensor
and hot film mass air flowmeter.
Attach fuel lines with new seal rings to fuel distributor pipe
– tightening torque 22.5 Nm / 16.6 lbf. ft.
If present: Attach cruise control Bowden cable with bracket to
intake manifold. Attach vacuum hose to intake manifold.
Insert accelerator Bowden cable in Bowden cable bracket.
For vehicles with manual transmission: Connect clutch actuation
pressure line and close retaining strap.
For vehicles with air conditioning: Connect refrigerant lines
and slide on rubber cover.
Attach brake servo vacuum line to brake servo.
Attach power steering pump suction line to power steering fluid
reservoir.
Attach high-pressure line to power steering pump –
tightening torque 28 Nm / 20.5 lbf. ft.
Attach upper coolant hose to thermostat housing.
Route engine wiring harness and attach multiple plug (screw-type
connection)
Insert engine wiring harness with rubber grommet into relay
frame and insert relay with relay frame socket.
Install engine control unit – see operation "Engine
Control Unit, Remove and Install".
Connect battery.
Inspect
Top up and bleed cooling system – see operation "Cooling
System, Top up and Bleed" and "Cooling System, Check for
Leaks".
For version with manual transmission: Bleed clutch actuation
– see operation "Hydraulic Clutch Actuation, Bleed" in group
"M".
Charge hydraulic system of power steering – see operation
"Hydraulic System, Charge and Bleed" in group "K".
Charge air conditioning – see operation "Air Conditioning,
Evacuate and Charge" in group "D".
1 ) Clean thread and insert bolts with bolt locking
compound (red).
2 ) Coat thread with assembly paste (white)
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