For 1990-2009 cars

#### Special Tools

• | J 37088-A Fuel Line Disconnect Tool Set

• | KM-161-B Bearing Puller

• | KM-468 Holding Bar

• | KM-807 Closure Plugs

• | KM-904 Base Frame

• | KM-6001-A Engine Mount

• | KM-J-34730-91 Pressure Tester

### Removal Procedure

1. Open the hood.
2. Disconnect the negative cable.

• | Remove the ground cables (4, 5) from the ground terminal (3).

• | Remove the 2 bolts.

• | Remove the ground connection from the negative terminal.

• | Loosen the bolt.

3. Disconnect the positive cable.

• | Remove the positive cable (2) from positive terminal (1).

• | Remove the bolt.

• | Remove the positive connection from the positive terminal.

• | Remove the bolt.

Warning: Refer to Battery Disconnect Warning in the Preface section.

4. Remove the battery.

• | Remove the bolt.

• | Remove the retaining plate.

5. Remove the battery support (1).

• | Disconnect the 2 coolant hoses (3).

• | Remove the wiring harness (4) from the battery support.

• | Remove the 2 cable ties.

• | Remove the 3 bolts (2).

6. Remove the radiator grille.

• | Remove the 4 body-bound rivets (1).

• | Disconnect from the front panelling from above.

• | Disconnect the 6 clips.

7. Evacuate the HVAC system. Refer to Refrigerant Recovery and Recharging.
8. Remove the steering column interim spindle.

• | Move the steering wheel to the straight-ahead position.

• | Remove the ignition key and engage the steering lock.

• | Remove the bolt (1).

9. Remove the coolant expansion tank (1).

Pull out of the bracket in the direction of the arrow.

10. Disconnect the steering wiring harness.

• | Remove the fuse carrier cover.

• | Remove the positive cable (2) from the fuse carrier.

• | Remove the nut (3).

• | Disconnect the wiring harness plug (1).

• | Expose the wiring harness.

• | Remove 2 from bracket.

11. Disconnect the wiring harness plug (1).

Release the retainer in the direction of the arrow.

12. For vehicles with manual transmission:

• | Disconnect the 2 gearshift cables (1) with KM-6042 (2).

• | Disconnect 2 from guide.

13. For vehicles with manual transmission:

• | Disconnect the 2 gearshift cables (1) with KM-6042 (2).

• | Disconnect 2 from guide.

14. For vehicles with automatic transmission:

• | Disconnect the gearshift cable (3) with KM-6042 (4).

• | Remove the gearshift cable from counterstay.

• | Remove the metal clip (1).

• | Press the locks (2).

15. For vehicles with automatic transmission, disconnect the 2 wiring harness plugs for the automatic transmission (1, 2).

16. For vehicles with automatic transmission:

• | Remove the wiring harness (2) from the automatic transmission.

• | Remove the 4 cable ties.

17. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
18. Remove the venting line (1) from the tank vent valve (2).
19. Place the collecting basin underneath.
20. Release the fuel pressure via the test connection (1) using KM-J-34730-91 .

Collect the exiting fuel in a suitable container. Refer to observe safety regulations and national legislation.

21. Remove the fuel return line (1).

• | Disconnect the quick-release fitting with J 37088-A .

• | Seal the fuel line and the fuel rail with KM-807 .

22. Disconnect the wiring harness plug (1).
23. Remove the engine management wiring harness.

• | Remove the ground cable (2) from the engine control unit.

• | Remove the bolt.

• | Disconnect the wiring harness plug (1).

• | Disconnect 3 from bracket.

24. Remove the brake servo vacuum line (1) from the intake manifold.

Disconnect the quick-release fitting.

25. For vehicles with manual transmission:

• | Remove the pressure hose, hydraulic clutch actuation (2).

• | Disconnect the retaining clamp (1) with a screwdriver.

• | Pull away the pressure hose.

• | Bend the clip together a little and insert back into the connecting piece.

26. For vehicles with manual transmission:

Disconnect the wiring harness plug, reverse gear switch (1).

27. Remove the front panelling at the top.

• | Remove the 2 bolts (1).

• | Remove the 2 body-bound rivets (2).

• | Disconnect the wiring harness connector.

28. Loosen the front wheels.
29. Raise the vehicle by half its height.
30. With the aid of an assistant, remove the front panelling.

• | Remove the 6 body-bound rivets (2).

• | Remove the 4 bolts (1).

Note: Push the front panelling upward at the side and pull out of the bracket.

31. Remove the front panelling.

• | Remove the front panelling from the bracket.

• | Disconnect the 4 clips.

• | Disconnect the outside temperature sensor.

32. Remove the front wheels.

Note: Use the spanner (1) to hold against flat surface.

33. Remove the swing arm (2) from the spring strut support tube.

Remove the 2 nuts.

34. Remove the tie rods from the steering knuckle with KM-161-B (3).

Remove the 2 nuts.

35. Remove the guide joints from the steering knuckle.

• | Remove the 2 screw connections.

• | Expand the steering knuckle bolts with KM-915 (4).

• | Pull the guide joints out of steering knuckle.

36. Remove the wheel arch inner panelling, left side.

Remove the body-bound rivet.

37. Disconnect the cooling module wiring harness plug (3).

• | Disconnect the wiring harness.

• | Disconnect the cable tie.

• | Remove the ground cable (2).

• | Remove the nut (1).

38. Remove the refrigerant line from the condenser (high pressure side).

Remove the bolt (1).

39. Raise the vehicle by half its height.
40. Remove the lower engine cover and the right engine splash guard.
41. Drain the coolant.

• | Place a drip pan underneath.

• | Install a suitable hose to drain connection (2).

• | Open the coolant drain screw (1).

• | Drain the coolant.

• | Close the coolant drain screw.

42. Remove the rear muffler (1).

• | Loosen the fastening clamp (3).

• | Remove the nut.

• | Remove from the bracket.

• | Remove the 2 rubber bearings (2).

• | Remove the end muffler from the front muffler.

43. Expose the catalytic converter control oxygen sensor wiring harness (1).

• | Disconnect the wiring harness (2).

• | Disconnect the wiring harness connector (3).

44. Remove the front exhaust pipe (2) from the catalytic converter (1).

Remove the 3 nuts (3).

45. Remove the front exhaust pipe.

Remove the 4 damper rings.

46. For vehicles with automatic transmission:

• | Place a drip pan underneath.

• | Drain the automatic transmission oil.

- | Remove drain bolt (1).

- | Release the transmission oil.

Caution: Refer to Fastener Caution in the Preface section.

- | Tighten the drain bolt with a new seal.

Tighten
Tighten the drain bolt to 40 N·m (30 lb ft).

47. For vehicles with automatic transmission, remove the wiring harness plug for the selector lever (1).
48. Insert KM-6173 (3).

• | Loosen the 4 bolts (arrows) and hand-tighten.

• | Align KM-6173 at the frame.

• | Wind up the support bearing (1).

• | The journal (2) must sit in the mount at the cylinder block.

• | Tighten the 4 bolts.

Note: Installing KM-6001-A guarantees perfect alignment of the drive unit with the frame.

49. Install KM-6001-A (1).

• | Loosen the 3 bolts (arrows) in the adjusting rails.

• | Insert KM-6001-A .

• | The journals (2, 5) must sit in the guide holes of the frame.

• | Tighten the 3 bolts in the adjusting rails.

• | Adjust the support bearings, front (4, 3).

| Note: The guide journals must be seated free from play in the support bearings.

• | Raise the support bearings up to the stop on the guide journals.

50. Lower the vehicle by its full height.
51. Disconnect the refrigerant line (low pressure side).

Remove the bolt (1).

Note: Mark the assignment using colored markings.

52. Remove the coolant hoses (1) from the heater core.

• | Place the collecting basin underneath.

• | Release the 2 quick-release fittings in the direction of the arrow.

• | Pull off the 2 coolant hoses.

53. Remove the right engine damping block from the engine damping block bracket.

Remove the 3 bolts (1).

54. Remove the left engine damping block from the engine damping block bracket.

Remove the 3 bolts (2).

55. Install KM-904 with KM-6390.

| Note: Use a hydraulic jack that can be lowered to a height of at least 100 cm (3.3 ft).

• | Attach to the hydraulic lifter.

• | Lower the centering pins (1).

• | Remove the 2 splines.

• | Inspect under the front frame, ensure there is no play.

• | Centering pins (2) must engage in the relevant holes in the frame.

Note: Note the different bolt lengths.

56. Remove the front frame.

Remove the 10 bolts (1, 2, 3, 4).

57. Move out the front frame.

### Installation Procedure

1. Remove the 2 closure caps (1, 2) from the underbody.
2. With the aid of an assistant, move the front frame back in.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the front frame.

Tighten
Tighten 10 new bolts to 90 N·m (67 lb ft) plus 45 degrees, plus 15 degrees.

4. Remove KM-904 with KM-6390.

• | Lower the hydraulic lifter.

• | Remove the KM-904 and the KM-6100 from the hydraulic jack.

5. Install the 2 covers in the underbody.
6. Lower the vehicle by its full height.
7. Install the right engine damping block to the engine damping block adapter.

Tighten
Tighten the 3 bolts to 55 N·m (41 lb ft).

8. Install the left engine damping block to the engine damping block adapter.

Tighten
Tighten the 3 bolts to 55 N·m (41 lb ft).

Note: It is imperative to adhere to the following assembly order.

9. Install the cooling hoses to the heater core.

• | Slide the 2 quick release fitting locking mechanisms in the direction of the arrow as far as they will go.

• | Plastic rings (green) will be covered.

| Note: Pay attention to the colored markings.

• | Install the 2 quick release fittings onto the heater core connecting piece (1) as far as they will go.

• | Slide the 2 quick release fitting locking mechanisms (3) in the direction of the arrow as far as they will go.

• | Plastic rings (green) must be visible.

• | Ensure the quick release fittings are correctly seated and that the plastic rings (arrows) are visible.

10. Connect the low pressure refrigerant line.

Use a new gasket.

Tighten
Tighten the bolt to 20 N·m (15 lb ft).

11. Raise the vehicle by its full height.
12. Remove KM-6173.

Undo the 4 bolts.

13. Remove KM-6001-A .

Loosen the 3 screwed connections.

14. For vehicles with automatic transmission:

Install the wiring harness plug for the selector lever.

15. With the aid of an assistant, insert the front exhaust pipe with the front muffler.

Install the 4 damper rings.

16. Install the front exhaust pipe to the catalytic converter.

• | Use a new gasket.

• | Use new nuts.

Tighten
Tighten the 3 nuts to 20 N·m (15 lb ft).

17. Install the rear muffler.

• | Install the rear muffler to the front muffler.

• | Install the 2 damper rings.

18. Align the exhaust system.
19. Connect the exhaust system.

Tighten
Tighten the screwed joint to 50 N·m (37 lb ft).

20. Connect the wiring harness plug for the catalytic converter control oxygen sensor.

Install the wiring harness.

21. Lower the vehicle by half its height.
22. Insert the 2 axle shafts into the wheel hub.

• | Insert the guiding joint into the steering knuckle.

• | Use new nuts.

Tighten
Tighten the 2 nuts to 90 N·m (67 lb ft) plus 75 degrees plus 15 degrees.

• | Counterhold at the wheel hub with KM-468 .

23. Install the 2 guide joints to the steering knuckle using new nuts.

Tighten
Tighten the 2 screwed joints to 50 N·m (37 lb ft).

24. Install the 2 tie rods to the steering knuckle using new nuts.

Tighten
Tighten the 2 nuts to 30 N·m (22 lb ft) plus 90 degrees plus 15 degrees.

Note: Use the spanner to counterhold against a flat surface.

25. Install the 2 swing arms to the spring strut support tube using new nuts.

Tighten
Tighten the 2 nuts to 55 N·m (41 lb ft).

26. Install the lower engine cover and the right engine splash guard.
27. Connect the cooling module wiring harness plug.

• | Install the ground cable.

Tighten
Tighten the nut to 5 N·m (44 lb in).

• | Install the wiring harness plug.

• | Install the 2 wiring harnesses.

28. Install the wheel arch inner panelling, left side.

Install the body-bound rivet.

29. Lower the vehicle by half its height.
30. With the aid of an assistant, install the front panelling.

• | Connect the 2 wiring harness plugs.

• | Install the front panelling on the side.

• | Install the 2 body-bound rivets.

31. Raise the vehicle by half its height.
32. Install the front panelling at the bottom.

Install the 6 body-bound rivets.

Tighten
Tighten the 4 bolts to 2.5 N·m (22 lb in).

33. Lower the vehicle by half its height.
34. Install the 2 front wheels and hand-tighten the 10 bolts.
35. Lower the vehicle by half its height.
36. Install the 2 front wheel.

Tighten
Tighten the 10 bolts to 110 N·m (81 lb ft).

37. For vehicles with manual transmission, connect the wiring harness plug, reverse the gear switch.
38. For vehicles with manual transmission, install the connection, hydraulic clutch actuation.

Note: Must engage audibly.

39. Install the brake force amplifier vacuum line.

Connect the quick release fitting.

40. Install the engine management wiring harness.

• | Connect the 2 wiring harness plugs.

• | Connect 3 in bracket.

• | Install the negative cable to the engine control unit.

Tighten
Tighten the bolt to 5 N·m (44 lb in).

41. Install the fuel supply line to the fuel rail.

• | Connect the quick release fitting.

• | Connect into the bracket.

• | Remove the 2 KM-807 .

42. Install the venting line to the tank vent valve.
43. For vehicles with manual transmission:

• | Install the 2 shift cables.

• | Connect 2 to the ball head.

• | Connect 2 in guide.

44. For vehicles with automatic transmission:

Connect the 2 wiring harness plugs for the automatic transmission.

45. For vehicles with automatic transmission:

• | Install the gearshift cable to the counterstay.

• | Install the metal clip.

• | Install in the gearshift cable.

46. Install the steering wiring harness.

• | Install the positive cable to the fuse carrier.

Tighten
Tighten the nut to 5 N·m (44 lb in).

• | Install the wiring harness plug.

• | Connect in the 2 wiring harnesses.

47. Install the coolant expansion tank.

Install the retaining clip.

48. Connect the wiring harness plug to the engine compartment electronics module.
49. For vehicles with manual transmission:

Bleed the hydraulic clutch actuator. Refer to Hydraulic Clutch Bleeding

50. For vehicles with automatic transmission:

• | Install the wiring harness to the automatic transmission.

• | Install the 5 cable ties.

51. Install the battery holder.

Tighten
Tighten the 3 bolts to 15 N·m (11 lb ft).

• | Connect in the bracket for the coolant hose.

• | Connect on the 2 wiring harness.

52. Install the battery.

• | Install the battery bracket.

Tighten
Tighten the bolt to 5 N·m (44 lb in).

• | Install the positive connection to the positive terminal.

Tighten
Tighten the nut to 5 N·m (44 lb in).

53. Install the positive cable to the positive terminal.

Tighten
Tighten the bolt to 5 N·m (44 lb in).

54. Charge the HVAC system. Refer to Refrigerant Recovery and Recharging.
55. Install the radiator grille.

• | Connect in 6.

• | Install the 4 body-bound rivets.

56. Install the steering intermediate spindle to the steering gear.

Coat the bolt with the screw locking compound (red) and insert.

Tighten
Tighten the bolt to 24 N·m (17 lb ft).

57. Connect the battery.

Install the negative connection to the ground terminal.

Tighten
Tighten the nut to 5 N·m (44 lb in).

58. Install the negative cable to the ground terminal.

Tighten
Tighten the 2 bolts to 5 N·m (44 lb in).

59. Install the wiring harness plug.
60. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling.
61. Install air cleaner housing. Refer to Air Cleaner Assembly Replacement.
62. For programming procedures, refer to Control Module References.
63. For vehicles with automatic transmission:

• | Pour in the transmission oil retained.

• | Inspect and correct transmission fluid level. Refer to Transmission Fluid Check.

64. Close the hood.