31 10 001 Completely removing and installing front axle with engine and transmission (N55 hybrid car)

Special tools required:

WARNING: High-voltage system - danger to life!
The following points must be strictly observed prior to starting work:

Disconnect HIGH-VOLTAGE SYSTEM FROM POWER
Observe SAFETY INFORMATION for handling with hybrid cars

IMPORTANT: When removing, note that the unit weights approx. 250 to 450 kg.
Check the vehicle payload.
Footwell at front is loaded with approx 200 kg.
Note safety information of TABLE LIFT !

Necessary preliminary tasks:

Position vehicle on vehicle hoist so its weight is centered.
Disconnect battery.
SUCTION OFF the air conditioning.
Remove EXPANSION TANK .
Remove FAN COWL with electric fan.
Drain COOLANT .
REMOVE bulkhead sound insulation.
Detach vacuum line from brake booster.
Detach ENGINE WIRING HARNESS in electronics box and set aside.
Remove complete PROPELLER SHAFT .
Remove front BRAKE PADS .
Remove both brake calipers at the front and hang them to one side.

Necessary preliminary work for engine or transmission replacement

Following repair work must be carried out before removal of the front axle support with a table lift.

Disconnect electrical machine from flywheel.

Remove cover (1).

Fig 1: Identifying Cover

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Crank engine at vibration damper in direction of rotation until nut (1) is visible in recess.

Release all 6 nuts of electrical machine.

Tightening torque 24 40 2AZ

Fig 2: Identifying Vibration Damper Nut

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Unlock and detach thermostat on radiator (1).

Fig 3: Identifying Thermostat On Radiator

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Release screw (1).

Tightening torque 17 22 4AZ .

Remove engine oil pipe from thermostat (2).

Release and disconnect coolant hoses (3).

Fig 4: Identifying Thermostat, Coolant Hoses And Screw

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Release hose clamp (1) with special tool 17 2 050 and detach coolant hose (2).

Fig 5: Identifying Hose Clamp

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Unlock and detach charge air line (1) and charge air pipe (2) of charge air cooler and set to one side.

Fig 6: Identifying Charge Air Line And Charge Air Pipe

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Release screws (1) from A/C lines.

Installation note:

Replace sealing rings.

Tightening torque 64 52 1AZ .

Raise A/C lines upward.

Unlock and disconnect high-voltage plug connection (2).

Fig 7: Disconnecting High-Voltage Plug Connection

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Release clamping bolts (1) on steering shaft at the bottom of the steering gear and pull off.

Installation note:

Clean screw threads to remove all remnants of screw locking adhesive.

Replace clamping bolts.

Tightening torque 32 31 2AZ .

Fig 8: Identifying Clamping Bolts On Steering Shaft

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Unlock and detach both electrical connectors (1) on steering gear.

Unclip cable routing from front axle support and fold back cable toward engine support.

Installation note:

Replace faulty cable clips.

Fig 9: Identifying Electrical Connectors On Steering Gear

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Recycling:

Catch and dispose of escaping fuel with auxiliary materials.

Observe country-specific waste disposal regulations.

Unclip high-voltage cable (1).

Release screws (2) and remove protective plate (3).

Fig 10: Identifying High-Voltage Cable, Protective Plate And Screws

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Unfasten fuel line (1) and disconnect.

Unlock and detach tank ventilation line of carbon canister (2).

Fig 11: Identifying Carbon Canister And Fuel Line

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Close off fuel line (1) with special tool 13 5 161 .

Close off fuel line (2) with special tool 13 5 162 .

Fig 12: Identifying Fuel Lines

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Release ground cable at body.

Fig 13: Identifying Ground Cable Body

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Release screws (1) from high-voltage connector (2).

Disconnect connector (2).

Tightening torque 12 36 2AZ .

Fig 14: Identifying High-Voltage Connector And Screws

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Release clamp (1) from holder.

Unfasten screws (2).

Release guide (3) with high-voltage cable from transmission.

Fig 15: Identifying High-Voltage Cable Guide, Clamp And Screws

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Open connector housing (1), pull electrical connection out of bracket and disconnect.

Disengage cable with rubber grommets from holders (2).

Installation note:

Check that the electrical connectors and rubber grommets are correctly mounted.

Fig 16: Identifying Connector Housing And Holders

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Note 31 00 MOBILE TABLE LIFT document.

IMPORTANT: Coordination of table lift from left to right.

Position engine on working surface of table lift A .

Position transmission on working surface of table lift A .

Work surface of table lift B can be adjusted in length (see arrow).

Fig 17: Positioning Engine Assembly On Table Top

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Structure of table lift.

Position adapter (50) on work surface of table lift B for transmission cross-member with coordinates 3/3 and 4/7.

Position adapter (80) on work surface of table lift B under transmission with coordinates 7/4.

Position adapter (60) on work surface of table lift A for front axle support with coordinates 2/1 and 2/8.

Position adapter (10) on work surface of table lift A for swivel bearing with coordinates 4/1 and 5/8.

Position adapter (70) on work surface of table lift A for front axle support with coordinates 7/2 and 7/7.

Fig 18: Positioning Adapter On Work Surface Of Transmission Cross-Member Table Lift

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Possible attachment points of front axle support (1 and 2) and transmission cross-member (3).

Fig 19: Identifying Front Axle Support Attachment Points

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Adapt and secure (3) wheel hub adapter (1) on left and right of wheel hub (2).

Fig 20: Securing Wheel Hub Adapter On Left And Right Of Wheel Hub

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Release left and right spring strut screws (2).

Tightening torque 31 31 1AZ .

Installation note:

Clean inside contact surface at spring strut dome.

Align spring strut with bore holes on spring strut dome using centering pins and push up.

Fig 21: Identifying Left/Right Spring Strut Screws

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Release screws (1).

Tightening torque 22 32 3AZ .

Fig 22: Identifying Screws

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Release screws (1) on left and right.

Tightening torque 51 11 6AZ .

Unclip cable tie (2).

Installation note:

Replace faulty cable clips.

Fig 23: Identifying Cable Tie And Screws

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Release bolts (1-3).

Carefully lower the front axle complete with the motor and transmission.

Installation note:

Note the installation location and tightening sequence of the screws.

Check threads for damage; if necessary, repair with HELICOIL THREAD INSERTS .

Bolt (1) M12x45
Screw (2) M12x165
Screw (3) M14x60

Tightening torque 31 10 1AZ .

Fig 24: Identifying Lower Front Axle Complete And Bolts

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Installation note:

Position the table lift beneath the vehicle.

Adjust the table lift to the vehicle inclination using the adjusting screw (2).

Fig 25: Positioning Table Lift Beneath Vehicle

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After installation:

Check and add engine oil.
Fill and bleed hydraulic system.
Check line connections for leak tightness
Check and clear the fault memory