11 00 050 Removing and installing engine with transmission (B48, B46): Notes
Special tools required:
When replacing the engine:
For all vehicles with engine B46 and engine B48 made before 11/2015, the DME needs to be reprogrammed after replacing the cylinder head.
Recycling:
Catch and dispose of escaping fuel with auxiliary materials.
Observe country-specific waste disposal regulations.
Attention !
Seal openings or lines on air conditioning with special tool 32 1 270 to prevent escape of media and contamination.
Necessary preliminary tasks:
- Remove ACOUSTIC COVER
- Remove REMOVE VEHICLE BATTERY
- Remove the POWER DISTRIBUTION BOX WITH CONTROL UNIT SUPPORT
- Remove FRONT AXLE COMPLETELY
- Remove both OUTPUT SHAFTS
- Remove STARTER MOTOR
- Drain off ENGINE OIL
- Remove CHARGE AIR COOLER
- Remove RADIATOR
REMOVAL:
Release clamp (1).
Replace clamp (1).
Disconnect the exhaust system from the catalytic converter.
Vehicles with manual transmission:
Disconnect the plug connection (2) on the neutral sensor.
Detach cable (1) with holder from transmission.
Vehicles with manual transmission:
Attention !
Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.
If possible, do not deflect push rod of clutch slave cylinder.
A deflection of the push rod caused by removal will cause easy escape of fluid. This escape of fluid does not mean that the clutch slave cylinder is damaged.
Exchange is therefore not necessary.
Release nuts (1) and remove clutch slave cylinder.
Unscrew nuts (1).
Disconnect positive battery terminal (2) and positive battery connection point (3).
Slacken screw (1) and remove ground cable from engine block.
Unlock and disconnect the connector (1).
Disconnect wiring harness (2) from engine wiring harness.
Detach the wiring harness at the clips (1) from the battery tray (4).
Detach the coolant hose (2) from the battery tray (5).
Loosen screws (3).
Remove battery tray (4).
Release coolant hose (1) and pull off connecting branch.
Shown with intake plenum removed for purposes of clarity.
Release clamp (1).
Pull hose (2) off connecting pipe (3).
Release vacuum line (1) connection and disconnect.
Vehicles with manual transmission:
Release clips on limit position/holder (2).
Detach selector lever cables (3) at ball joints.
Vehicles with automatic transmission:
Unlock and disconnect the connector (1).
Release clips on limit position/holder (2).
Detach selector lever cable (3) at ball joint.
Slacken screw (1) and remove ground strap (2).
Disconnect fuel line (1).
Catch and dispose of escaping fuel.
Seal fuel lines with special tools 13 5 160 and 13 5 162 .
Unlock coolant line (1) and pull off.
Detach coolant line (1) from front end.
Unfasten screws (2).
Remove refrigerant lines (3).
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings without damaging them.
Release screws (1).
Remove holder (2).
Vehicle with manual transmission:
Prepare MOBILE TABLE LIFT :
Position transmission on table top B.
Structure of table lift.
Position fixture (30) with fixture (40) for engine block on table top A at coordinates 6/6 and 1/7 (1).
Position the fixture (30) with fixture (50) for the oil sump on table top A at coordinates 5/3 and 2/3 (2).
Position fixture (30) with fixture (80) for transmission housing on table top B at coordinates 6/5, 2/5 and 2/7 (3).
Position fixture (83 30 2 357 221) for transmission housing on table top B at coordinates 7/3 (4).
Vehicle with automatic transmission:
Prepare MOBILE TABLE LIFT :
Position transmission on table top B.
Structure of table lift.
Position fixture (30) with fixture (40) for engine block on table top A at coordinates 6/5 and 2/6 (1).
Position the fixture (30) with fixture (50) for the oil sump on table top A at coordinates 4/2 and 2/3 (2).
Position fixture (30) with fixture (80) for transmission housing on table top B at coordinates 9/6, 7/6 and 8/2 (3).
Position fixture (83 30 2 357 221) for transmission housing on table top B at coordinates 6/3 (4).
Attention !
Removal weight approx. 150 kg to 300 kg.
Check payload of the motor vehicle, if applicable unload.
Load front footwell with sandbags if necessary, approx. 100 kg.
Note safety instructions of TABLE LIFT .
Vehicles with manual transmission:
Position table lift under the engine.
Abut all fixtures and screw to the table lift.
Vehicles with manual transmission:
Screw fixture (83 30 2 357 221) to the housing for the clutch slave cylinder.
Vehicles with automatic transmission:
Position table lift under the engine.
Abut all fixtures and screw to the table lift.
Vehicles with automatic transmission:
Screw fixture (83 30 2 357 221) to the transmission housing with screw (1).
Release screws (1).
Release screw connection (1) of right engine support.
Carefully raise the vehicle.
Take care when removing the engine!
Risk of damage of the compressor (1) at the deformation element (2).
Slightly slide the table lift with the engine in direction of arrow.
Remove engine with transmission.
Loosen TRANSMISSION .
Slide table top B in direction of arrow and remove transmission.
Attach workshop crane and lift engine from lifting table.
INSTALLATION:
Vehicles with manual transmission:
Prepare MOBILE TABLE LIFT :
Position transmission on table top B.
Structure of table lift.
Position fixture (30) with fixture (40) for engine block on table top A at coordinates 6/6 and 1/7 (1).
Position the fixture (30) with fixture (5) for the oil sump on table top A at coordinates 5/3 and 2/3 (2).
Position fixture (30) with fixture (80) for transmission housing on table top B at coordinates 6/5, 2/5 and 2/7 (3).
Position fixture (83 30 2 357 221) for transmission housing on table top B at coordinates 7/3 (4).
Vehicle with automatic transmission:
Prepare MOBILE TABLE LIFT :
Position transmission on table top B.
Structure of table lift.
Position fixture (30) with fixture (40) for engine block on table top A at coordinates 6/5 and 2/6 (1).
Position the fixture (30) with fixture (50) for the oil sump on table top A at coordinates 4/2 and 2/3 (2).
Position fixture (30) with fixture (80) for transmission housing on table top B at coordinates 9/6, 7/6 and 8/2 (3).
Position fixture (83 30 2 357 221) for transmission housing on table top B at coordinates 6/3 (4).
Attention !
Take care when installing the engine!
Risk of damage of the compressor (1) at the deformation element (2).
Vehicles with manual transmission:
Place engine and transmission on table lift.
Mount transmission on engine.
Vehicles with manual transmission:
Screw fixture (83 30 2 357 221) to the housing for the clutch slave cylinder.
Lower vehicle.
Vehicles with automatic transmission:
Place engine on table lift.
Mount TRANSMISSION ON ENGINE .
Vehicles with automatic transmission:
Screw fixture (83 30 2 357 221) to the transmission housing with screw (1).
Lower vehicle.
Position table lift with engine and transmission under the vehicle.
Carefully lower the vehicle.
Tighten screws (1) on transmission carrier.
Tightening torque 22 32 1AZ .
Tighten screws (1) on right engine support.
Tightening torque 22 11 1AZ .
Position holder (2).
Tighten down screws (1).
Join refrigerant lines (3) to compressor.
Tighten down screws (2).
Tightening torque 64 53 4AZ .
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to mount sealing rings without damaging them.
Connect and lock coolant line (1).
Route coolant line (1) correctly in the front end.
Remove special tools 13 5 160 and 13 5 162 .
Connect fuel line (1).
Position ground strap (2) and tighten screw (1).
Vehicles with manual transmission:
Attach selector lever cables (3) at ball joints.
Fasten limit position/holder (2) with clips.
Vehicles with automatic transmission:
Connect the connector (1).
Attach clip at limit position/holder (2).
Attach selector lever cable (3) to ball joint.
Connect vacuum line (1).
Connect hose (2) to connecting pipe (3).
Fasten clamp (1).
Place coolant hose (1) on connecting branch and lock.
The intake plenum will be removed for purposes of clarity.
Join wiring harness (2) and engine wiring harness.
Connect the connector (1).
Connect positive battery terminal (2) and positive battery connection point (3).
Tighten down nuts (1).
Secure ground cable (2) with screw (1).
Install battery tray (4) and secure with screws (3).
Attach coolant line (2) to battery tray (4).
Secure the wiring harness to the battery tray (4) with clips (1).
Vehicles with manual transmission:
Slowly relieve tension on clutch slave cylinder otherwise air may be drawn in through sealing sleeve.
If possible, do not deflect push rod of clutch slave cylinder.
A deflection of the push rod caused by removal will cause easy escape of fluid.
This escape of fluid does not mean that the clutch slave cylinder is damaged.
Exchange is therefore not necessary.
Carefully insert clutch slave cylinder and tighten nuts (2).
Tightening torque 21 52 1AZ .
Vehicles with manual transmission:
Connect connector (2) of neutral gear sensor.
Fasten cable (1) with holder on transmission.
Slide the exhaust system onto the catalytic converter.
Tighten clamp (1).
Tightening torque 18 20 1AZ .
Required follow-up work:
- Top up ENGINE OIL
- Check cooling system for leaks.