Removing Engine

WARNING: This page is about a different variant/trim than selected.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapours.

→ Attach warning sign in a clearly visible position.

→ Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.

→ Secure collection containers/vessels to prevent them from tipping over.

WARNING: Caustic fluids

Danger of chemical burns
→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ Avoid contact with caustic fluid.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

NOTE: NOTIFICATION
Aggressive fluids

Risk of damage to components and surfaces
→ Do not spill fluids.

→ In the event of contact, wash the component or surface with water.

→ Replace components that are already damaged.

Information

For installation, it is a good idea to mark the installation position of the front-axle carrier diagonally at least two places on the body. To do this, place the marks vertically with respect to the floor of the body using a felt-tip pen (e.g. mark along the front-axle carrier mount with the pen). This makes it easier to correctly position the front-axle carrier on the body during re-installation.

Information

Because of the high loosening torques, the four fastening screws on the front-axle carrier and the two screws on the engine transverse bar can now be loosened. Loosen the screws by a maximum of one turn.

Information

When lowering the engine, make sure that no cables, hoses or lines are fitted between the engine and body.
Get a second person to help you check this.

Information

The pictures shown in this document may differ from the original.

Release electric plug connection -1- - M - on the DME control unit -2- (-a- ) and pull it off -A- .

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Plug connection on DME control unit
Loosen fastening nut -1- for ground point at the body and remove ground cable -2- to the DME control unit.
Cut the tie-wrap if necessary.

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Ground point on body
Remove the tie-wrap -3- if necessary.
Open the cover of the front relay box in the plenum panel.
>WM 970955 REPLACING SUB-PART OF WIRE HARNESS IN ENGINE COMPARTMENT AT THE LEFT
Release and unplug the three electric plug connections -1- on the engine wire harness.

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Disconnecting plug connections
Unclip the engine wire harness -1- in the plenum panel from the retaining clips -2- and remove it.

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Engine wire harness in plenum panel
Disconnect B+ transfer point at the left of the engine compartment.

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B+ transfer point
Release electric plug connections -1- at the left cross panel -a, b- and pull them off -A, B- .

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Plug connections at left cross panel
Release electric plug connections -1- at the right cross panel -a, b- and pull them off -A, B- .

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Plug connections at right cross panel
Lay the engine wire harness on the engine and secure it.
Remove intake pipe.
>WM, 243519 REMOVING AND INSTALLING COWL FOR THROTTLE HOUSING (Y-PIPE) "Removing"
Drain the hydraulic fluid reservoir -1- and the PDCC reservoir -2- , if necessary, using a suitable tool.
Then remove the hoses -3, 4- at the tanks and close them off using suitable stoppers.

> 489719 Removing and installing reservoir - "REMOVING "

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>WM, 430955 REPLACING RESERVOIR (PDCC) "Removing"

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Hoses for hydraulic reservoir
Loosen the fuel line -1- at the plenum panel.

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Plenum panel lines
Release the clamp -2- on the tank ventilation line.
Pull the vacuum hose -3- off the lower part -4- of the line.
Disconnect the coolant line -1- from the coolant reservoir -2- at the bleeder valve.

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Coolant lines at the reservoir
Loosen the clamp -3- on the coolant hose -4- at the coolant reservoir -2- .
Pull off the coolant hose.
Loosen clamps -1- on the coolant hoses -2- at the top of the engine.

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Coolant hoses at top of engine

Pull off coolant hoses -2- .
Loosen the clamp -1- on the vacuum line -2- at the vacuum pump -3- and pull off the vacuum line.

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Vacuum pump line
Raise the vehicle.
Unscrew fastening screws -1, 2- for holders -3, 4- for brake hydraulic lines.

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Holders for hydraulic lines
Loosen holders from the wheel bearing housing -5- .
Release electric plug connections -1- for the speed sensor on the wheel bearing housing -a- and pull them off -A- .

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Plug connections on wheel bearing housing (shown as an example)
Remove the brake calliper and suspend it at a suitable position in the wheel arch > Suspending brake calliper (do not open brake hydraulics!).
Also protect the brake calliper (e.g. with a cloth or suitable rubber mat) to prevent damage to the paintwork.

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Suspending brake calliper
Remove fastening screws -1- for the connecting links -2- at the bottom of the anti-roll bar -3- .

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Connecting link for anti-roll bar
Press out the ball joint between the wheel carrier and upper wishbone using > T10187 - ball joint puller.
Unscrew the fastening screw -2- for the spring strut -3- and at the same time, raise the axle support -1- as far as required using a suitable jack -4- so that the fastening screw can be unscrewed easily.

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Removing spring strut mounting
Disconnect the ground point on the right longitudinal member. -arrow-

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Ground point on right longitudinal member
Loosen the fastening screw -1- on the holder -2- for ATF lines -3- at the thermostat -4- .

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ATF lines from thermostat to transmission
Place a suitable container underneath to catch emerging ATF.
- Pull ATF lines out of the thermostat.
- Close off the ATF lines and bores on the thermostat using suitable stoppers.
Loosen fastening screws -1- on the heat shield -2- at the steering gear.

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Heat shield for steering gear

Remove heat shield -2- .
Loosen the clamping screw -1- on the steering column -2- at the steering gear -3- .

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Loosening steering column at the steering gear

Slide the steering column -2- upwards -arrow- and pull it down off the steering gear -3- (-A- ).
Pull clamps -1- off the coolant lines -2- for the heating water heat exchanger in the engine compartment at the rear left on the wheel housing.

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Coolant lines in front left wheel housing
Pull off coolant hoses -2- .
Loosen the fastening screw -1- for the refrigerant line -2- at the front left longitudinal member -3- and pull out the line.

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Front left refrigerant line
Remove the line -1- from the air-conditioning compressor to the condenser -2- .

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Line from air-conditioning compressor to condenser
1. 36.1 To do this, unscrew the fastening screw -3- for the line -1- at the condenser -2- .
2. 36.2 Close off lines and connection pieces.
Loosen the clamp -1- on the hydraulic line -2- in the front left wheel housing and pull the hose off the hydraulic line.

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Front left hydraulic line

Close off the line and connection piece using suitable stoppers.
Loosen the cardan shaft at the transfer gear using a mounting lever and tie it up.
>WM, 390219 REMOVING AND INSTALLING FRONT CARDAN SHAFT "Removing"
Release electric plug connections -1, 2- at the right of the transfer gear -a, b- and pull them off -A, B- .

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Plug connections for transfer gear at the right
Release electric plug connections -1, 2- at the bottom of the transfer gear -a, b- and pull them off -A, B- .

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Plug connections for transfer gear at the bottom
Mark gearshift position - N - -1- on automatic transmission -2- with a suitable pen -A- .

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Marking gearshift position
Remove shift cable -3- on automatic transmission -4- .
> 371519 Removing and installing selector lever cable - "REMOVING "

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Removing shift cable
1. 42.1 Unclip the cable -3- at the front of the ball joint -1- using > VAS 6933 - Disassembly tool.
2. 42.2 Unscrew fastening screws -2- on the shift cable -3- .
Loosen fastening nuts -8- on the exhaust clamp (clamping sleeve) -3- between the catalytic converter and exhaust system. Slide exhaust clamps onto the exhaust system. The exhaust clamps must not be re-used.
> 260119 Removing and installing exhaust system - "REMOVING "

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Loosening clamps
Mark the installation position of the front-axle carrier diagonally at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation. > Marking installation position of front-axle carrier

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Marking installation position of front-axle car
Set up the lifting platform according to instructions
> 100119 Removing and installing engine - "TOOLS AND MATERIALS "

Then position it under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body. > Lifting platform under engine

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Lifting platform under engine
The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view from below here).

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Mounting points for front-axle carrier
Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)- , -4 into the body- .

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Lifting platform
Secure the wheel bearing housing. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and lifting platform. -arrow-

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Securing wheel bearing housing
Mark the final position of the lifting platform -1- on the workshop floor using a suitable tool, e.g. adhesive tape -A- .

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Position of lifting platform
Loosen the transmission cross member. To do this, loosen the four fastening screws -A- .

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Fastening screws on transmission cross member
Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar. -arrows-

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Fastening screws for front-axle carrier and fastening screws for engine transverse bar (centre)
Get a second mechanic to help.
1st mechanic: Lower the lifting platform slowly by approx. 20 to 30 cm.

2nd mechanic: Observe the lowering process and check that the components, hoses and lines have sufficient clearance.