Removal & Installation

Necessary preliminary tasks:  

• Disconnect battery, grounding strap to body.
• Remove heater bulkhead
• Move engine bonnet/hood into assembly position with special tool 51 2 170.

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1. Remove cover for fuel injectors.
2. Remove upper section of suction filter housing with mass air flow sensor.

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3. Assemble special tool 00 0 200 with special tools 00 0 201 / 00 0 202 / 00 0 204 / 00 0 208 and fit.
4. Attach special tool 11 0 020 as shown in illustration to special tool 00 0 200.

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5. Secure special tool 11 0 020 to front and rear engine suspension eyes.
   IMPORTANT: Make sure no lines or cables on rear side of engine are damaged by chain.
   The supports (1) of special tool remove 00 0 208 must make contact with the screws on the side walls.

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6. Tighten down screws (1 and 2).

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7. Release top nut from left and right engine mounts.

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8. Raise engine with special tool 00 0 200 approx. 5 mm.
9. Remove reinforcement plate: 
   IMPORTANT: Read and follow manufacturer's operating instructions for vehicle hoist.
   Do not exceed approved load-carrying capacity and load distribution of vehicle hoist.
   Weight compensation may be necessary due to the loading situation of the vehicle.
   This also applies in the event of considerable removal of parts or conversions on the vehicle.
   WARNING: Risk of damage! Before driving onto a vehicle hoist, make sure there is sufficient ground clearance between the vehicle hoist and the vehicle. The vehicle may only be raised with the vehicle hoist at the four jacking points. All four jacking points (1) must be available! Never raise the vehicle without the jacking points (1)! Align support plates (2) of lifting platform arms to jacking points (1) in such a way that no adjoining components are taped and thereby damaged. Align the rubber block (2) with the jacking points (1) in such a way that no adjoining components are taped and thereby damaged. Never raise the vehicle without rubber blocks (or rigid foam blocks)! There is a major risk of damage to the vehicle underbody!

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   IMPORTANT: Driving without reinforcement plate is not permitted! 
   Release screws (1). Release screws (2). Remove reinforcement plate. Installation:  Replace screws and nuts. Tightening torque: Jointing torque: 56 Nm Torque angle: 90°
   NOTE: Replace screws & nuts
10. Remove front splash guard.
11. Remove front 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT .
12. Unfasten steering spindle from steering gear. This is described in 32 13 060 REMOVING AND INSTALLING POWER STEERING GEAR

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    NOTE: Output shaft is not pressed out of drive flange. Output shaft (1) and swivel bearing (2) remain together as a single unit during removal and installation.
13. Remove left and right swivel bearings (this procedure is part of "Removal" of output shafts).
14. Remove output shafts. Refer to AXLE SHAFTS (FRONT) .

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15. As shown in illustration, support front axle carrier with special tool 00 2 030 in conjunction with special tool 31 2 220 and a block of wood.
16. Detach front axle carrier from engine carrier.

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17. Lowering front axle:
    • Replace original screws in succession with screws of E38 front axle carrier (part number 9 900 223).
    • Screw in replaced screws (1) approx. 20 mm (axle lowers).
18. Installation: Check threads for damage; if necessary, repair with the appropriate Helicoil thread inserts. Front axle alignment is not required.
19. Tightening torque for front axle carrier: Thread: M12 10.9 Jointing torque: 50 Nm Torque angle: 90°

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20. Remove left engine mount.
21. Pull off vent hose.

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22. Release screws (1) and remove front differential. Tightening torque: 55 Nm Carefully feed out front differential towards bottom.
    IMPORTANT: If an assembly ring is already fitted, it must be removed. Carry out this task before inserting new sealing ring with assembly ring.

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23. Installation: Insert new sealing ring (1) in groove and apply antiseize agent.

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24. Installation: Push on assembly ring (1) up to sealing ring.

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25. Installation: The assembly ring (1) ensures that the sealing ring (2) is not damaged when the front differential is installed at the engine oil sump. When the front differential is installed at the engine oil sump, the assembly ring (1) is pushed over the sealing ring (2) and remains fitted.