Lowering The Engine By 50 To 60 Mm

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

WARNING: Danger of objects or lo ads falling down

Risk of squashing or crushing
→ Secure components to prevent them from falling down.

CAUTION: Risk of material damage when lowering engine

Damaged components must be replaced.
→ Get one or two more people to help.

Information

There are two ways of lowering the engine

Lower engine by 50 to 60 mm (lifting platform can be used)
Lower engine by 90 to 100 mm (lifting platform cannot be used)

Loosen oil filler neck -1-.

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Oil filler hose on oil filler neck

Unscrew screw -2- and place oil filler neck -1- on engine.
Detach coolant hose -1- at the left-hand side of the engine compartment.

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Left coolant hose

Release spring clamp -2- and disconnect coolant hose -1- .

Close off line connections using suitable stoppers and re-fit the spring clamp -2- .

Check O-ring for damage and replace it if necessary.
Disconnect supply connecting lines for engine cooling and heating -2- .

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Coolant hoses on coolant reservoir

Remove spring clamps -1- and pull off supply connecting lines for engine cooling and heating -2- .

Close off line connections using suitable stoppers and re-fit the spring clamps -1-

Check O-ring for damage and replace it if necessary.
Disconnect vent lines -1- from the coolant reservoir.

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Vent lines on coolant reservoir

Release locks -2- , disconnect and pull off vent lines -1- .

Close off openings using stoppers.

Check O-ring for damage and replace it if necessary.
Disconnect coolant hose -1- in the engine compartment at the right and vacuum lines.

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Right coolant hose and plug-in couplings for vacuum lines

Release spring clamp -2- and disconnect coolant hose -1-

Check O-ring for damage and replace it if necessary.

Close off line connections using suitable stoppers and re-fit the spring clamp -2- .

Release and disconnect plug-in couplings -3- .
Disconnect the fuel and tank vent line -1 and 2- .

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Connection for tank vent line and fuel line in engine compartment

Open retaining clip -3- and unclip fuel and tank vent line -1 and 2- .
Disconnect electric line for oxygen sensor downstream of catalytic converter -1-

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Electric plug connection for oxygen sensor downstream of catalytic converter

Release and disconnect electric plug connection -2- .

Unclip electric line for oxygen sensor downstream of catalytic converter -1- and electric plug connection -2- from the holders -3- .

Place electric line for oxygen sensor downstream of catalytic converter -1- on the engine.
Loosen differential pressure sensor -1- on both sides.

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Differential pressure sensor

Release and disconnect electric plug connection -2- .

Unclip differential pressure sensor -1- from holder -3- and place on the engine.
Disconnect exhaust temperature sensor control unit -1- and electric lines -2- .

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Exhaust temperature sensor control unit

Release and disconnect electric plug connection -3- .

Unclip exhaust temperature sensor control unit -1- from holder -4- .

Unclip electric lines -2- from holders -5- .

Open holder -6- and remove electric lines -2- .
Release and disconnect electric plug connection -1- on exhaust flap adjuster -2- .

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Electric plug connection for electric exhaust flap adjuster
Remove cover on engine control unit (DME) -2- .

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Cover on engine control unit (DME)

Unscrew nuts -1- .

Remove cover on engine control unit (DME) -2- .

Information

The electric plug connections on the DME control unit are colored differently and the position on the control unit is marked with colored dots accordingly.
Release and disconnect the front three electric plug connections -2- on the engine control unit (DME) -1-

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Electric plug connections on engine control unit (DME)
Release and disconnect electric plug connections for engine wire harness -1- at the right-hand side of the engine compartment.

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Electric plug connection for engine wire harness
Disconnect intake manifold -1- and molded hose -4- .

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Intake manifold and molded hose on turbocharger

Loosen V-band clamp -2- .

Right side only: Loosen vent line -3- and pull off intake manifold -1- .

Undo screw-type clamp -5- and remove molded hose -4- .
Loosen trailing arm -1- on both sides of the outer wheel carrier.

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Lower trailing arm, left

Unscrew nut -2- and counter at screw -3- at the same time.

Replace screws and nuts.

Information

You will need a second mechanic to help you with this step.
Loosen rear axle carrier -1- and lower.

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Rear axle carrier mounting

> VAS 6931 - Engine and gearbox jack must be positioned under rear axle carrier -1-

Unscew sirews -2 and 3- on both sides.

Lower rear axle carrier -1- with anti-roll bar and secure with tie-wraps.
Prepare tools for lowering the engine.
> 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ASSEMBLY SUPPORT
Prepare engine for lowering using > 9959 - lowering tool .
Support the engine using > VAS 6832 - Master Gear unit elevating platform with > 9769 - retainer plate and > 9769/1 - support .

Unscrew screws securing engine mount -2- to engine mount bracket -1- on both sides.

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Screw securing engine mount to engine mount bracket

Information

Adjust tilt angle of the lifting platform plate -1- according to the installation position of the engine/transmission unit -Arrow- .

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Tilt angle of lifting platform (view of side tilt angle)
Carefully lower the engine until the distance -Dimension A- between the engine mount -1- and engine mount bracket -2- is 50-60 mm.

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Dimension A
Secure engine using > 9959 - lowering tool.

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Lowering tool 9959

Position > 9959 - lowering tool -2- .

Screw in screws -1 and 3 - as far as they will go.