Removing Engine

→ Let hot components cool down.

→ Wear personal protective gear.

→ First relieve pressure in the clutch system.

→ Actuate the clutch pedal at least 25 times for this purpose.

→ Avoid contact with hot parts or sources of ignition.

→ Use suction to remove ignitable vapors.

→ Attach warning sign in a clearly visible position.

1. Before opening the fuel lines, place a warning sign in a clearly visible position on the vehicle. →
   Fig 1: Symbolic Representation Of Warning Sign

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   Information 

   • The steps for removing the air-conditioning compressor are not necessary for vehicles without air conditioning. 
2. Loosen union nuts (a/f 17) for fuel lines -1 and 2-  at the fuel cooler. Always counter with an open-ended wrench (a/f 14) while doing this.
   1. 2.1. Soak up emerging fuel with a cloth.
      Fig 2: Identifying Fuel Cooler Connections

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3. Mark the rolling direction of the drive belt (with a paint marker, for example). Check the drive belt and pulleys for signs of damage.
4. Relieve drive belt and remove from the pulleys.

   → 137819 REMOVING AND INSTALLING DRIVE BELT - GT2 RS .

   WARNING: Danger of injury and material damage when using Pentosin.

   • Risk of skin irritation and damage to skin.
   • Damage to hoses and wiring.

   → Wear protective gloves and goggles.

   → In the event of contact (eyes or skin), wash immediately with water.

   → Collect emerging Pentosin.

   → Use caps to protect the wiring against soiling and damage.

   → Clean hoses and wiring immediately.

5. Open hydraulic return line -1-  for power steering.

   → 489819 REMOVING AND INSTALLING HYDRAULIC PUMP .

   1. 5.1. Open spring band clamp -2-  and open line connection.
      Fig 3: Identifying Power-Steering Connection Position

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6. Disconnect hydraulic line on pressure side with plug-in coupling at the reservoir.

   → WM 489719 REMOVING AND INSTALLING RESERVOIR FOR HYDRAULIC PUMP .

   1. 6.1. Disassembly tool Nr.21  must be inserted between the line -2-  and the red circlip -1-  in order to release it by pulling the black line to the right, while at the same time pressing the tool against the red circlip.
      Fig 4: Identifying Power-Steering Line

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   2. 6.2. Close off lines -1-  (-2-  ) and insert them into a plastic bag -3-  in order to collect any more fluid that leaks out. Secure the bag with a tie-wrap -4-  to prevent it from falling off.
      Fig 5: Securing Hydraulic Lines In Bag

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7. Remove throttle housing. Unscrew four M6 fastening screws -arrows-  and remove cable plug for electronic accelerator.
   1. 7.1. Replace seal.
      Fig 6: Locating Throttle Housing Screws

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8. Open rapid-action couplings for fuel supply -1, 2 and 3-  in left of engine compartment. Press release buttons and simultaneously pull off the line.
   1. 8.1. Soak up emerging fuel with a cloth.
      Fig 7: Identifying Fuel Line Connections

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9. Disconnect vacuum line for the brake booster.
   WARNING: Caustic fluids

   • Danger of chemical burns

   → Avoid contact with caustic fluid.

   → Wear personal protective gear.

   → Ensure that there is good ventilation.

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

10. Disconnect the breather hose -4-  at the coolant reservoir. Open spring band clamp -3-  and pull off the hose.
    Fig 8: Identifying Fuel Lines, Coolant Ventilation And Brake Booster Vacuum Line

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11. Open supply hose from coolant reservoir -3-  and large coolant hose (Henn coupling) -2-  on the left. Loosen spring band clamp -4-  and spring clamp -1-  and pull off hoses.
    Fig 9: Identifying Coolant Supply Hose And Left Henn Coupling

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12. Open large coolant hose (Henn coupling) on the right. Loosen spring clamp and pull off hose.
13. Disconnect the air conditioning compressor. The air conditioning system must not be opened in order to do this.

    → WM 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

14. Place air conditioning compressor at the body/engine compartment on a solid base with the connected hoses.
15. Disconnect engine wire harness (2 round connectors with bayonet locks) from the plug connections in the right of the engine compartment. To do this, open the bayonet locks by turning them anti-clockwise.
    Fig 10: Identifying Engine Wire Harness Round Connectors

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16. Open tie-wrap -arrow-  on the cable guide for the engine wire harness and lay wire harness on the engine.
    Fig 11: Locating Engine Wire Harness Attachment Point

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17. Open oxygen-sensor plug connections and connector strip for exhaust temperature sensor.
    Fig 12: Identifying Oxygen Sensor And Exhaust Temperature Sensor Connector

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18. Remove anti-roll bar. Unscrew two fastening screws -1-  and a hexagon nut -2-  at the left and right. Counter at the collar nut with a Torx insert.
    Fig 13: Identifying Rear Anti-Roll Bar Mount

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19. Remove front cross member -A-  and the two diagonal braces -B-  .
    Fig 14: Removing Running Gear Braces

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    Information 

    • Remove upper hexagon-head bolts for the cross member so as to avoid damaging the reference mark sender cable and oil tank when lowering the engine/transmission unit. 
20. Remove the rear cross member -C-  .
    1. 20.1. Screw off four fastening nuts -arrows (C)-  and counter at the screws while doing so.
    2. 20.2. Pull out lower screws and remove bracket, then take out the upper screws.
    3. 20.3. U-profiles are used for the threaded joints on the bracket to make disassembly/assembly easier.
       Fig 15: Locating Cross Member Mount

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21. Fit drain plugs with new sealing rings on the coolant pipes and tighten them.

    → Tightening torque: 10 Nm (7.5 ft. lb.) +5 Nm (+3.5 ft. lb.) 

    Fig 16: Locating Coolant Drain Plug

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22. Fit special tool Adapter Plate 9510/1 -1-  to the wheel mount on the brake disc in order to counter when loosening the drive-shaft bolts.
    Fig 17: Removing Drive-Shaft Bolts

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23. Loosen drive-shaft bolts on the transmission side.

    → WM 422119 REMOVING AND INSTALLING REAR DRIVE SHAFT .

    1. 23.1. To protect the coating, wrap a cloth around the shafts and place them on the axle support.
24. Pull off cable plug -1-  for reversing light on transmission.
    1. 24.1. If the locking clip on the cable plug cannot be pressed (switch screw-in position), the switch must be loosened.
       Fig 18: Identifying Reversing Light Switch Cable Plug

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25. Loosen the coolant hoses on the transmission. Open spring band clamps and pull off hoses. Collect emerging coolant.
    Fig 19: Identifying Coolant Hoses (Manual Transmission)

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26. Screw out four M10 hexagon nuts and two M10 x 55 hexagon-head bolts -arrows-  on the transmission bracket and remove bracket.
    Fig 20: Locating Transmission Bracket Bolts

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27. Disengage shift cables.

    → WM 341219 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES .

28. Loosen electric connection lines on the starter.

    → 276019 REMOVING AND INSTALLING STARTER .

    1. 28.1. To do this, remove the protection cap on the solenoid switch and unscrew and remove the fastening nuts on the line for terminal 30 -1-  , terminal 50 -2-  on the starter.
       Fig 21: Removing Protection Cap On Solenoid Switch And Electric Connections

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    Information 

    Check for cuts on the entire diameter of the inner rubber edge on the pressure hose leading to the turbocharger. Replace if damaged.

29. Loosen the pressure hose on the turbochargers. Open the screw-type clamp -1-  and pull off the hose -2-  .
    Fig 22: Identifying Pressure Hose, Turbocharger And Charge-Air Cooler

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30. Disconnect engine ground strap on the body. Screw off hexagon nut -1-  and remove cable -2-  .
    Fig 23: Identifying Engine Ground Strap

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31. Open clutch pressure line.
    1. 31.1. Loosen threaded connection -A-  - make sure to counter with an open-ended wrench when doing this -B-  . Collect emerging hydraulic fluid and close off the lines.
       Fig 24: Locating Clutch Pressure Line

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32. Remove crash support. Re-fit nuts and bolts immediately after removal. → Tightening torque: 23 Nm (17 ft. lb.) 
    Fig 25: Locating Crash Support

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33. Prepare lifting platform and use the following special tools for removal: Secure the mounting plates on each side using two nuts and bolts -2-  at the position shown (observe hole pattern on lifting platform).

    Engine Retainer Plate 9111/3 

    Adapter 9111/1 

    Spacer 9111/4 

    Spacer 9111/5 

    Additional Support 9111/6 

    Fig 26: Identifying Engine Retainer Plate And Lifting Platform

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34. Position lifting platform with pre-fitted engine retainer plate slightly tensioned on the engine. The Spacer 9111/5  must be locked in a horizontal position.
    Fig 27: Identifying Engine Retainer Plate Spacer

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35. Loosen collar nuts on transmission bracket.
36. Loosen collar nuts on engine carrier from the engine mounts (wrench size 18).
    NOTE: Engine/transmission unit lowered or inserted incorrectly

    • Risk of damage to engine/transmission unit
    • Cables and coolant hoses can be stretched and torn

    → Gradually lower or raise the engine using a jack.

    → Always check that all necessary cables were disconnected when lowering the engine/transmission unit.

    → Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.

    → Get one or two more persons to help.

    Information 

    • Get a second person to check the clearance when lowering the engine/transmission unit. 
    • If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted in order to maintain structural strength. 
37. Lower the engine/transmission unit carefully and in steps.
    Fig 28: Identifying Lifting Platform Under Vehicle

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