Removing engine
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WARNING:
Hot surfaces.
Risk of burning!
Risk of burning!
- Perform all work only on components that have cooled down.
WARNING:
Car may slip off the vehicle hoist where components are supported.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Secure the vehicle hoist against lowering and lifting.
- Make sure that the vehicle does not lift off the mounting plates on the vehicle lift.
WARNING:
Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Ensure specific weight compensation on the vehicle.
WARNING:
Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly. Danger!
Immobilization period-threatening injuries!
Immobilization period-threatening injuries!
- Observe safety instructions on raising the vehicle using a vehicle hoist.
- For additional information see: RAISING THE VEHICLE WITH A VEHICLE LIFT .
WARNING:
Working on 12V electrical system.
Risk of short circuits! Risk of fire!
Risk of short circuits! Risk of fire!
- Make sure that there is no charger connected to the jump start terminal in the engine compartment.
- Detach battery ground lead from battery.
- For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.
WARNING:
Working on fuel system.
Risk of fire! Danger of explosion!
Risk of fire! Danger of explosion!
- When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
- Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
- No fire, sparks, open flames or smoking.
CAUTION:
On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!
Injury hazard!
- Wear suitable personal protective equipment.
- Before performing any installation work, allow cooling system to cool down to less than 40°C.
- Note warnings on cylinder head cover.
NOTE:
RISK OF DAMAGE
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train.
- After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
- It is imperative you observe the repair notes for cylinder head or engine replacement.
- For additional information, see: REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT .
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Preliminary work
- Refer to DEACTIVATING ELECTRICAL SYSTEM .
- Refer to MOVING THE HOOD TO THE SERVICE POSITION .
- Refer to REMOVING THE SEAL FOR THE HOOD REAR .
- Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
- Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
- Refer to REMOVING LEFT AND RIGHT WIPER ARM .
- Refer to REMOVING THE COWL COVER .
- Refer to REMOVING THE ACOUSTIC COVER .
- Refer to REMOVING THE TENSION STRUT AT THE SHOCK TOWER ON THE LEFT AND RIGHT .
- Refer to REMOVING THE FIREWALL UPPER PART .
- Refer to REMOVING ACOUSTIC COVER AT REAR .
- Refer to REMOVING RIGHT SEALING FRAME .
- Refer to REMOVING THE SECOND FIREWALL AT THE BOTTOM .
- Refer to REMOVING ALL IGNITION COILS .
- Refer to REMOVING FUEL DELIVERY LINE .
- Refer to REMOVING RESONATOR .
- Refer to REMOVING CLEAN AIR PIPE .
- Refer to REMOVING CHARGE AIR LINE .
- Refer to REMOVING THE LAMBDA OXYGEN SENSOR .
- Refer to REMOVING THE FRONT ACOUSTIC COVER FOR THE ENGINE .
- Refer to RELEASING THE ELECTRIC AUXILIARY COOLANT PUMP FOR THE CHARGE AIR COOLER AND/OR AIR CONDITIONING CONDENSER .
- Refer to REMOVING THE DRIVE BELT FOR ALTERNATOR .
- Refer to REMOVING THE DME CONTROL UNIT .
- Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
- Refer to REMOVING CONTROL UNIT BRACKET .
- Refer to REMOVING THE FRONT LEFT AND RIGHT WHEELS .
- Refer to IF INSTALLED: REMOVING THE UNDERBODY PLANKING OF THE TRANSMISSION ON THE SIDE .
- Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
- Refer to REMOVING THE CENTER UNDERBODY PROTECTION .
- Refer to REMOVING REAR UNDERBODY PROTECTION .
- Refer to REMOVING BOTTOM LEFT FRONT WHEEL ARCH COVER .
- Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY ON THE RIGHT .
- Refer to REMOVING THE COVER FOR THE STEERING ASSEMBLY ON THE RIGHT .
- Refer to RELEASING THE RIGHT AND LEFT TIE ROD FROM THE SWIVEL BEARING .
- Refer to RELEASING THE LEFT AND RIGHT OUTPUT SHAFT FROM THE WHEEL BEARING .
- Refer to RELEASING WISHBONE ON RIGHT AND LEFT FROM SWIVEL BEARING .
- Refer to REMOVING RIGHT OUTPUT SHAFT .
- Refer to REMOVING OUTPUT SHAFT .
- Refer to REMOVING TANK COVER ON LEFT AND RIGHT .
- Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
- Refer to REMOVING EXHAUST SYSTEM .
- Refer to REMOVING CATALYTIC CONVERTER .
- Refer to REMOVING STARTER MOTOR .
- Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM .
- Refer to CONNECTING THE COOLANT LINES FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to CONNECTING THE COOLANT HOSE TO THE AUXILIARY COOLANT PUMP .
- Refer to REMOVING THE HEAT SHIELDS .
- Refer to REMOVING THE RETAINING PLATES .
- Refer to PARTIALLY LOOSENING THE PROP SHAFT .
- Refer to REMOVING THE AUTOMATIC TRANSMISSION (ALL-WHEEL DRIVE VEHICLE) .
- Refer to INSTALLING THE SPECIAL TOOL ON THE CYLINDER HEAD .
WARNING:
Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Observe safety instructions on raising the vehicle using a vehicle hoist.
- For additional information see: RAISING THE VEHICLE WITH A VEHICLE LIFT .
WARNING:
Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Ensure specific weight compensation on the vehicle.
WARNING:
Working on 12V electrical system.
Risk of short circuits! Risk of fire!
Risk of short circuits! Risk of fire!
- Make sure that there is no charger connected to the jump start terminal in the engine compartment.
- Detach battery ground lead from battery.
- For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.
WARNING:
Working on fuel system.
Risk of fire! Danger of explosion!
Risk of fire! Danger of explosion!
- When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
- Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
- No fire, sparks, open flames or smoking.
WARNING:
Contact with hazardous fluids.
Hazardous to health!
Hazardous to health!
- Note and follow safety instructions on containers.
- Conduct all work in appropriate personal protective equipment only.
CAUTION:
Heavy component.
Heavy components can lead to injury or damage.
Heavy components can lead to injury or damage.
- Remove and install heavy components with the aid of another person/other persons.
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
- Prepare the special tool 2 220 718
.
- Prepare special tool 0 490 567 (11 0 020)
.
- Remove the cover (2) from the latch mechanisms (1).
- Remove the cover (2) in an upwards direction.
- Loosen nuts (1).
- Remove the positive battery cable (2) and set it aside.
- Remove the positive battery cable (3) and set it aside.
- Loosen clamp (1).
- Unlock and release lock (2).
- Guide the fuel feed line (3) out and set it aside.
- Catch and dispose of escaping fuel.
- Unlock and disconnect the tank ventilation line (4).
- Unlock and disconnect the vacuum line (1).
- Unlock and release the coolant lines (1) and (2).
- Catch and dispose of escaping coolant.
- Unlock and loosen coolant line (1).
- Catch and dispose of escaping coolant.
- Unlock and loosen coolant line (1).
- Unlock and loosen coolant line (1).
- Catch and dispose of escaping coolant.
- Unlock and release coolant line (1) at the electric coolant pump (2).
- Catch and dispose of escaping coolant.
- Release the clamping collar (1) with the special tool 0 495 794 (17 2 050).
- Feed out the coolant hose (2) in direction of arrow and set it aside.
- Catch and dispose of escaping coolant.
- Unlock and loosen clamp (1).
- Feed out the coolant hose (2) and set it aside.
- Unlock and release the coolant lines (1) up to (3).
- Catch and dispose of escaping coolant.
- Unlock lock (1).
- Thread out holder (2) and set aside.
- Unlock and loosen coolant line (1).
- Catch and dispose of escaping coolant.
- Loosen screw (1).
- Thread out holder (2) and set aside.NOTE: TECHNICAL INFORMATION
Only loosen the air conditioning compressor, do not remove it.
Do not draw off the refrigerant.
Do not loosen the refrigerant lines. - Unlock plug connection (1) and disconnect.
- Loosen screws (2).
- Slide the air conditioning compressor (3) out and set it aside.
- Secure air conditioning compressor (3) against falling down with special tool 2 413 317 .
- Loosen screw (1).
- Loosen screw (1).
- Guide out and remove manifold support (2).
- Unlock and release transmission oil line (1).
- Unlock and release transmission oil line (2).
- Catch and dispose of escaping transmission oil.
- Loosen screws (1).
- Feed out the transmission oil lines (2) and remove.
- Catch and dispose of escaping transmission oil.
- Have all the special tools and commercially available tools ready.
Number Description 1 Standard torque wrench 2 Extension 11 9 150 3 External Torx E14 - Assemble all the special tools and commercially available tools as shown.
- Release screw (1) of the left engine mount from the bottom.
- Release screw (1) on the right engine mount from the top with a commercially available tool.
- Hook the special tool 0 490 567 (11 0 020) to the special tool 2 220 718 (2).
- Hook the special tool 0 490 567 (11 0 020) to engine mounting bracket (1).
- Hook the special tool 0 490 567 (11 0 020) to special tool 2 459 012 .
- Feed out the combustion engine with the special tool 2 220 718 (2) and lift it out.