Removing V6 Hybrid Engine

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 cables, hoses or lines are not trapped accidentally between the engine and body. To prevent this, a second person must make sure that the cables, hoses and lines do not get caught  .

Information 

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

1. Remove air guide pipe by pulling off the hose -1-  and loosening the hose clamps -arrows-  .
   Fig 1: Locating Air Guide Pipe

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2. Disconnect all connectors -1... 4-  for oxygen sensors.
   Fig 2: Identifying Oxygen Sensor Connectors

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3. Remove windscreen wiper arms. → REMOVING WIPER ARMS
4. Remove plenum panel cover.
5. Remove anti-theft protection from the engine control unit.
6. Pull engine wiring harness connector off the engine control unit.
7. Unscrew ground strap and disconnect connector. -arrows- 
   Fig 3: Locating Ground Strap And Connector

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8. Place engine wire harness on the engine.
   1. 8.1. Open cover of central electrical system.
   2. 8.2. Disconnect all connectors whose wires go to the engine.
   3. 8.3. Remove engine wire harness from the plenum panel and place it on the engine.
      Fig 4: Identifying Central Electrical System Cover

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   WARNING: Hot fluid

   • Danger of scalding

   → Let the fluid cool down.

   → Wear personal protective gear.

9. Pull off coolant hose -1-  () and disconnect vent lines -arrows-  .
   Fig 5: Locating Coolant Hose And Vent Line

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   WARNING: Hot fluid

   • Danger of scalding

   → Let the fluid cool down.

   → Wear personal protective gear.

10. Pull off secondary-air line -1-  and coolant hoses -arrows-  .
    Fig 6: Locating Secondary-Air And Coolant Hoses

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    WARNING: Hot fluid

    • Danger of scalding

    → Let the fluid cool down.

    → Wear personal protective gear.

11. Pull off coolant hoses -arrows-  .
    Fig 7: Locating Coolant Hoses

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    CAUTION: Escaping residual air

    • Risk of eye injuries

    → Wear protective goggles.

    NOTE: Opened refrigerant system for repairs.

    • Risk of moisture getting into the refrigerant system.
    • Risk of contaminating the refrigerant circuit.
    • Risk of saturation and irreparable damage to desiccator.
    • Irreparable damage to the desiccator can damage the compressor and evaporator.

    → After opening the refrigerant circuit, close off the lines/connections immediately using suitable stoppers.

    → The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left open for a long time.

12. Disconnect refrigerant line for air conditioning. Close off open lines using suitable stoppers.
    Fig 8: Locating Engine Refrigerant Line

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13. Remove crash panel on power and control electronics for electric drive. → REMOVING FUSE FOR POWER ELECTRONICS UNIT
    WARNING: Hot fluid

    • Danger of scalding

    → Let the fluid cool down.

    → Wear personal protective gear.

14. Open the locks on the two rapid-action couplings -arrows-  and pull off the coolant lines.
    Fig 9: Opening Coolant Lines

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15. Release and pull off the high-voltage line for the electric air-conditioning compressor -1-  .
    Fig 10: Pulling Air-Conditioning Compressor High-Voltage Line

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16. Release and unplug the pilot connector -1-  at the power electronics. Release and pull off the high-voltage lines -2, 3, 4-  one after the other. Unclip high-voltage lines and place them on the engine.
    Fig 11: Removing Pilot Connector And High-Voltage Lines For Electric Motor

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    NOTE: Opened refrigerant system for repairs.

    • Risk of moisture getting into the refrigerant system.
    • Risk of contaminating the refrigerant circuit.
    • Risk of saturation and irreparable damage to desiccator.
    • Irreparable damage to the desiccator can damage the compressor and evaporator.

    → After opening the refrigerant circuit, close off the lines/connections immediately using suitable stoppers.

    → The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left open for a long time.

17. Unplug connector on the air-conditioner compressor -arrow-  . Unscrew screw -1-  and remove refrigerant line from the air-conditioner compressor.
    Fig 12: Identifying Air-Conditioning Compressor Connector

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    WARNING: Emerging fuel

    • Danger of fire or explosion

    → Do not work on the fuel system when the engine is hot.

    → Wear personal protective gear.

    → Attach warning sign in a clearly visible position.

    → Keep clear of naked flames and ignition sources.

18. Disconnect the fuel supply line -arrow-  .
    Fig 13: Locating Fuel Supply Line

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19. Disconnect connector -arrow-  at the steering gear.
    Fig 14: Locating Steering Gear Connector

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20. Remove heat shield -1-  for universal joint.
    Fig 15: Locating Heat Shield On Universal Joint

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21. Remove universal joint -1-  from the steering gear and push it upwards. Pull off hoses -2-  on the coolant pipes.
    Fig 16: Identifying Universal Joint And Hoses

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22. Unscrew ground strap on drive motor -arrow-  .
    Fig 17: Locating Drive Motor Ground Strap

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23. Unscrew clamp -1-  . Pull out securing clasp -arrow-  and remove bleeder for clutch actuation. Close off open lines.
    Fig 18: Locating Clutch Actuation Bleeder

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24. Release front right wheel housing liner, disconnect connector for auxiliary hydraulic pump control unit and expose wire harness.
    Fig 19: Locating Auxiliary Hydraulic Pump Control Unit Connector

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25. Unscrew ground strap -A-  on the right longitudinal member.
    Fig 20: Identifying Ground Strap On Longitudinal Member

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26. Unscrew screw -A-  and pull connections off the transmission oil cooler. Collect emerging oil.
    Fig 21: Identifying Transmission Oil Cooler Connections

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27. Clamp power-steering hose using hose clamp 3094  . Disconnect power steering lines -arrows-  . Collect emerging oil.
    Fig 22: Locating Power-Steering Lines

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    WARNING: Hot fluid

    • Danger of scalding

    → Let the fluid cool down.

    → Wear personal protective gear.

28. Disconnect coolant hoses -arrows-  and remove upper coolant hose -1-  from the brackets.
    Fig 23: Locating Coolant Hoses

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29. Press off trailing arm.
    1. 29.1. Unscrew nut for upper trailing arm by several turns and press off the joint using ball joint puller T10187  .
    2. 29.2. Completely unscrew nut and disconnect trailing arm.
       Fig 24: Pressing Trailing Arm

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30. Disconnect connectors -arrow-  from the front speed sensors at the left and right.
    Fig 25: Locating Speed Sensor Connectors

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31. Disconnect connector -arrow-  for wear indicator.
    Fig 26: Locating Wear Indicator Connector

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32. Unscrew screws -arrows-  for line bracket.
    Fig 27: Locating Line Bracket Screws

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33. Unscrew screw -arrow-  on connecting link at the bottom.

    Screw off nut -A-  on double wishbone. Leave the screw in the bore hole.

    Fig 28: Locating Connecting Link And Double Wishbone Screw

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34. Unscrew screws -A-  on the brake calliper, remove brake calliper and secure in the wheel housing with a tension strap.

    Repeat these steps for the wheel suspension on the opposite side of vehicle.

    Fig 29: Identifying Brake Caliper Screws

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35. Disconnect connector -arrows-  at the transmission.
    Fig 30: Locating Transmission Connector

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36. Remove exhaust system.
    1. 36.1. Release clamping sleeves -1-  and -2-  between the front and center silencers.
       WARNING: Danger of objects or loads falling down

       • Risk of squashing or crushing

       → Secure components to prevent them from falling down.

    2. 36.2. Support the exhaust system between the center silencer and rear silencer with engine and gearbox jack. Unscrew exhaust system mountings and lower the exhaust system.
       Fig 31: Identifying Exhaust System Clamping Sleeves

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37. Remove rear cardan shaft. → REMOVING REAR CARDAN SHAFT
38. Disconnect shift mechanism at the ball joint and unscrew from transmission.
    Fig 32: Locating Shift Mechanism

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39. 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 re-installation. → Marking installation position of front-axle carrier 
    Fig 33: Marking Front-Axle Carrier Installation Position

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40. Set up the lifting platform according to instructions

    → Removing V6 Hybrid Engine  . 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 

    Fig 34: Identifying Engine Platform

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41. The -arrows-  show the mounting points for the mounting frame in the front-axle carrier (view from below here).
    Fig 35: Locating Front-Axle Carrier Mounting Points

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42. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)-  , -4 into the body-  .
    Fig 36: Lifting Engine Platform

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43. 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- 
    Fig 37: Locating Wheel Bearing Housing Bolt

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44. Remove screws -A-  for the right and left spring struts.
    Fig 38: Locating Connecting Link And Double Wishbone Screw

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45. Mark the final position of the lifting platform -1-  on the workshop floor using a suitable tool, e.g. adhesive tape -A-  .
    Fig 39: Position Engine Lifting Platform

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46. Loosen the transmission cross member. To do this, loosen the four fastening screws -A-  .
    Fig 40: Identifying Transmission Cross Member Screws

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47. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
48. Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar. -arrows- 
    Fig 41: Locating Front-Axle Carrier And Fastening Screws

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49. 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.

    NOTE: Lowering power unit

    • Risk of damage to connections

    → Disconnect all connections to the body.

    WARNING: Danger of objects or loads falling down

    • Risk of squashing or crushing

    → Secure components to prevent them from falling down.

    Slowly lower the power unit while constantly checking clearance.