Removing The Engine

NOTIFICATION 

Opened refrigerant system for repairs. 

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

Information 

When lowering the engine, make sure not to damage the brake line holder and plug connections on the brake calliper.

Information 

Before removing the engine, the vehicle must be secured using tension straps to prevent it from tipping due to weight loss.

Permissible fastening points are:

• lower hinges on front doors 
• Lifting platform arms 

1. Have suitable stoppers ready for closing off the line connections.
2. Have suitable aids ready for soaking up emerging fluids.
3. Remove oil pipe -1-  .

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   Oil pipe on oil mist separator

   1. 3.1  Turn oil pipe -1-  anti-clockwise to open it. -Arrow- 
   2. 3.2  Remove oil pipe -1-  .
4. Vehicles with particle filter: 

   Release and disconnect electric plug connection for differential pressure sensors -1-  at the right and left.

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   Electric plug connection on differential pressure sensor

5. Vehicles with particle filter: 

   Release and disconnect electric plug connection for exhaust temperature sensors -1-  at the left and right and unclip from holder -2-  .

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   Electric plug connection for exhaust temperature sensor

   Information 

   The number of plug connections and clips can vary depending on equipment and engine variant of the vehicle.

6. Disconnect electric wire harness for engine -1-  .

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   Electric wire harness for engine

   1. 6.1  Release and disconnect all  electric plug connections -2-  .
   2. 6.2  Unclip clips -3-  .
   3. 6.3  Unclip electric wire harness for engine -1-  at the side of the engine control unit holder.
   4. 6.4  Set electric wire harness for engine -1-  aside.
7. Remove pressure hose -1-  on both sides of the vehicle.

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   Pressure hose

   1. 7.1  Loosen screw-type -2-  clamps.
   2. 7.2  Disconnect pressure hose -1-  .
   3. 7.3  Close off connections using stoppers.
8. Disconnect vacuum line for brake booster -1-  .

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   Brake booster vacuum line

   1. 8.1  Disconnect brake booster vacuum line connection -2-  .
   2. 8.2  Close off line connections using suitable stoppers.
9. Release and disconnect electric plug connections for engine mounts -1-  and wire harness for steering gear -2-  .

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   Electric plug connections for engine mounts and wire harness for steering gear

10. Unclip electric wire harness for the engine mount from the front-axle carrier and set it aside in such a way that it cannot be damaged when lowering the engine.
11. Disconnect wire harness for level sensors -1-  .

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    Wire harness for level sensors

    1. 11.1  Release and disconnect electric plug connections for level sensors -2-  .
    2. 11.2  Unclip clips -3-  .
    3. 11.3  Move wire harness for level sensors -1-  aside.
12. Disconnect electric wire harness for anti-roll bar -1-  .

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    Routing of electric wire harness for anti-roll bar (shown on V6 biturbo)

    1. 12.1  Unclip line clips -2-  .
    2. 12.2  Unclip clip -3-  .
    3. 12.3  Release and disconnect electric plug connection (signal connector) -4-  .
    4. 12.4  Release and disconnect electric plug connection (engine phase connector) -5-  .
    5. 12.5  Unscrew nut on ground line -6-  .
    6. 12.6  Guide electric wire harness for anti-roll bar -1-  out towards the anti-roll bar and out of the wheel housing, but do not disconnect it from the anti-roll bar.
13. Disconnect electric plug connection -2-  .

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    Electric plug connection on holder in wheel housing

    1. 13.1  Unscrew screw -1-  .
    2. 13.2  Remove electric plug connection -2-  from holder and release and disconnect it.
14. Disconnect coolant hose -1-  .

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    Coolant hose for auxiliary heating

    1. 14.1  Loosen spring band clamp -2-  using > VAS 6890 - spring band clamp pliers  .
    2. 14.2  Disconnect coolant hose -1-  from coolant pipe -3-  .
15. Loosen electric plug connection -1-  .

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    Electric plug connection

    1. 15.1  Disconnect ground points.
       1. 15.1.1  Unscrew nuts -4-  .
       2. 15.1.2  Move round lines -5-  aside.
    2. 15.2  Release and disconnect electric plug connection -1-  .
    3. 15.3  Unscrew screws on holder -2-  .
    4. 15.4  Disengage electric plug connection -1-  from holder -3-  and remove holder.
16. Loosen cable duct in engine compartment -1-  .

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    Ground line and positive cable in engine compartment

    1. 16.1  Set coolant reservoir aside.
    2. 16.2  Unscrew nut on positive cable -2-  .
    3. 16.3  Unscrew screw on ground line. -3- 
    4. 16.4  Unscrew screw on cable duct at the top -4-  .
    5. 16.5  Unscrew nut on cable duct at the bottom -5-  .
    6. 16.6  Disengage cable duct -1-  in a downward direction and set it aside.
    7. 16.7  Secure coolant reservoir back in its original position using at least one screw.
17. Disconnect coolant vent line -1-  .

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    Coolant vent line

    1. 17.1  Unclip coolant vent line -1-  from clip -2-  .
    2. 17.2  Release and disconnect coolant vent line -1-  at connection point -3-  in the engine compartment.
    3. 17.3  Close off line connections using suitable stoppers.

    Information 

    The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

18. Loosen holder for electric lines -3-  .

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    Electric lines for brake

    1. 18.1  Disconnect electric lines for the brake -1-  .
       1. 18.1.1  Disengage electric lines -1-  and plug connection -2-  from holder -3-  .
       2. 18.1.2  Release and disconnect electric plug connections for wheel speed sensor -4-  and brake pad wear indicator -2-  .
    2. 18.2  Unscrew screw on holder for electric lines -5-  .
    3. 18.3  Remove retaining clip -6-  .
    4. 18.4  Remove holder for electric lines -3-  .

    Information 

    The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

19. Disconnect electric line -1-  on the acceleration sensor.

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    Wire harness for acceleration sensor

    1. 19.1  Release and disconnect electric plug connection -2-  .
    2. 19.2  Disengage electric line -1-  from holder -3-  .

    Information 

    The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

20. Loosen front brake calliper -1-  .

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    Front brake calliper

    1. 20.1  Unscrew screws on brake calliper -3-  .
    2. 20.2  Remove front brake calliper -1-  .

    Information 

    Do not suspend the brake calliper on the brake line or on the electric line for the brake pad wear indicator.

21. Hang the brake calliper -1-  at a suitable position in the wheel housing.

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    Brake calliper in wheel housing (shown as an example)

    1. 21.1  Protect brake calliper -1-  with a cloth to prevent paint damage.
22. Remove heat shields on longitudinal member.

    > 261420 REMOVING AND INSTALLING HEAT SHIELDS

23. Loosen side brackets -1-  and sliding elements -2-  .

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    Bracket and sliding element

    1. 23.1  Unscrew screw on sliding elements -3-  .
    2. 23.2  Unscrew screws on bracket -4-  .
    3. 23.3  Remove bracket -1-  and sliding elements -2-  .
24. Disconnect coolant hose for radiator -1-  .

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    Coolant hose on radiator

    1. 24.1  Release and disconnect coolant hose connection -2-  .
    2. 24.2  Release and disconnect electric plug connection -3-  .
    3. 24.3  Set coolant hose -1-  aside.
    4. 24.4  Close off connections using stoppers.
25. Disconnect pressure hoses -1-  on pressure pipe -2-  .

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    Pressure hose on pressure pipe

    1. 25.1  Loosen screw-type -3-  clamps.
    2. 25.2  Pull off pressure hoses -1-  .
26. Disconnect coolant hose -1-  .

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    Coolant hose

    1. 26.1  Loosen spring band clamp -2-  fusing > VAS 6890 - spring band clamp pliers  .
    2. 26.2  Detach coolant hose -1-  .
    3. 26.3  Close off line connections using suitable stoppers.
27. Release and disconnect electric plug connections -2-  on the pressure sensors -1-  .

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    Electric plug connections for pressure sensor

28. Loosen ATF cooler -1-  .

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    ATF cooler

    1. 28.1  Release and disconnect line connection for coolant hose -2-  .
    2. 28.2 Only if automatic transmission is removed:  Unscrew screws on ATF cooler -3-  .
    3. 28.3 Only if automatic transmission is removed:  Hang ATF cooler -1-  at the side.
    4. 28.4  Close off line connections using suitable stoppers.

    Information 

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    Steering wheel alignment gauge (example)

    • For fast and reliable steering wheel alignment in centre position, use a > VAS 6826 - Steering wheel balance (with integrated angle measurement box)  .
29. Fix the steering wheel -A-  in the centre position with the steering wheel lock. Use only steering-wheel holders that do not project into the area of the airbag unit -B-  Shorten the guide rod of the steering-wheel holder at the top if necessary -Arrow-  .

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    Steering-wheel holder (example)

30. Disconnect universal joint for steering -1-  from the steering gear -2-  .

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    Universal joint for steering

    1. 30.1  Unscrew screw on universal joint -3-  .
    2. 30.2  Disconnect universal joint -1-  from the steering gear -2-  .

    Information 

    To make it easier to turn the engine, the drive belts can be removed from the generator and air-conditioning compressor.

    > Removing and installing drive belt (V8 biturbo) 

    Information 

    For loosening/tightening the screws on the drive plate, always counter at the central screw on the vibration damper. The help of another person is required.

31. Only if automatic transmission is removed following removal: 

    Unscrew drive plate screws -1-  .

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    Drive plate screws

    1. 31.1  Remove cap -2-  .
    2. 31.2  Unscrew drive plate screw -1-  .
    3. 31.3  Turn the engine further and repeat the procedure on all drive plate screws -1-  .
32. Release and disconnect electric plug connection on automatic transmission -1-  .

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    Electric plug connection for automatic transmission

33. Disconnect electric wire harness for transmission -1-  .

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    Electric wire harness for automatic transmission

    1. 33.1  Release and disconnect electric plug connections on automatic transmission -2 and 3-  and -5-  .
    2. 33.2  Unclip clips -4-  on electric wire harness for transmission.
    3. 33.3  Set electric wire harness for transmission -1-  aside.
34. Disconnect coolant hose -1-  .

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    Coolant hose

    1. 34.1  Release and disconnect line connection -2-  .
    2. 34.2  Set coolant hose -1-  aside.
    3. 34.3  Close off line connections using suitable stoppers.
35. Release and disconnect line connection for coolant hose at the radiator -1-  .

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    Coolant hose on top of radiator

    Information 

    The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

36. Remove connecting link -3-  and loosen shock absorber fork.

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    Connecting link and shock absorber fork

    1. 36.1  Loosen threaded joint -1 and 2-  and remove connecting link -3-  .
    2. 36.2  Dismantle threaded joint -4-  securing shock absorber fork.
37. Fit > VAS 6832/8 - universal assembly device  on > VAS 6832 - Master Gear unit elevating platform  and position it under the engine.
38. Unscrew screws on front-axle carrier -1 to 4-  .
    Fig 1: Front Axle Carrier Screws Loosening Sequence

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    Screw on front axle carrier

    1. 38.1  Unscrew screw on front-axle carrier -1-  .
    2. 38.2  De-burr the bore.
    3. 38.3  > T40327 - Locating pin  must be screwed into the bore hole and tightened.

       If it is difficult to guide > T40327 - locating pins  into the bore, the affected area must be deburred beforehand using a suitable tool.

       Tightening torque: 20 Nm 

    4. 38.4  Repeat the procedure in the sequence -2 to 4-  for all other screws on the front-axle carrier.
39. Unscrew rear screws on front-axle carrier -1-  and screws on transmission support -2-  .

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    Rear screws on front-axle carrier

40. Remove side brackets -1-  and sliding elements -2-  .

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    Bracket and sliding element

41. Guide engine on > VAS 6832 - Master Gear unit elevating platform  down out of the vehicle.