Removing Engine

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

WARNING: Vehicle can fall down

Risk of squashing or crushing
Risk of damage to the vehicle
→ Do not place any solid objects under the raised vehicle.

→ Ensure that the lifting platform is prevented from lowering.

→ Remove solid objects before lowering the vehicle.

→ Raise the vehicle only at the jacking points provided.

→ The outer jacking points should be used primarily.

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.

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 vapors.

→ 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.

CAUTION: Risk of material damage when lowering engine

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

CAUTION: Hot components

Risk of burns
→ Let hot components cool down.

→ Wear personal protective gear.

Information

Adjust tilt angle of the lifting platform -1- plate 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)

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.
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 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 -1-.

Unclip differential pressure sensor -1- from holder -3- and place it 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-.
Remove cover for DME control unit -2-.

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Cover for DME control unit

Unscrew nuts -1- and remove cover from DME control unit -1-.

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 DME control unit -1-

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Electric plug connections on DME control unit
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 refrigerant lines -1 and 2- .

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Refrigerant line connections in engine compartment

Unscrew screws -3 and 4- at connection points -Arrows- .

Close off line connections using suitable stoppers and move refrigerant lines -1 and 2- aside.

Information

Make sure that the drive shaft does not hang down as this may damage the joint.
Loosen drive shaft -1- on both sides of the transmission flange.

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Drive shaft on transmission flange (shown without wheel)

Unscrew bolts -2- and get another person to help by countering and turning each wheel one after the other.

Secure drive shaft -1- to prevent it from falling down.
Remove rear wheels.
440519 REMOVING AND INSTALLING WHEEL

440519 REMOVING AND INSTALLING WHEEL WITH CENTRAL BOLT
Release and disconnect electric plug connection -1- on electric exhaust flap adjuster --2- .

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Electric plug connection for electric exhaust flap adjuster
Disconnect intake pipe -1- and molded hose -4- from the intake air line and turbocharger on both sides.

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Intake pipe and molded hose on turbocharger

Loosen V-band clamp -2- .

Right side only:

Loosen vent line -3- and pull off intake pipe -1- .

Loosen screw-type clamp -5- and pull off molded hose -4- .
Disconnect electric line at both ends.

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Oxygen sensor upstream of catalytic converter

Release and disconnect electric plug connection -2- .

Unclip electric line -1- from clip -3- .
Disconnect coolant hose -1- at the right-hand side of the engine compartment and vacuum lines.

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Right coolant hose and plug-in couplings for vacuum lines

Release spring clamp -2- and pull off coolant hose -1- .

Check O-ring and replace it if necessary.

Close off line connections using suitable stoppers.

Release and disconnect plug-in couplings -3- and pull off vacuum lines.
Before opening the fuel line, attach or mount a warning sign -1- in a clearly visible position at or on the vehicle.

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Warning sign when working on the fuel system
Disconnect fuel line and tank vent line -1 and 2- .

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Connection for tank vent line and fuel line in engine compartment

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

Catch escaping fuel and close off line connections using suitable stoppers.
Disconnect vent lines -1- from coolant reservoir.

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Vent lines on coolant reservoir

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

Close off line connections using suitable stoppers.

Check O-rings and replace them if necessary.
Disconnect coolant hose -1- at the left-hand side of the engine compartment.

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Left coolant hose

Release spring clamp -2- and pull off coolant hose -1- .

Close off line connections using suitable stoppers.

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

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Coolant hoses on coolant reservoir

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

Close off line connections using suitable stoppers.

Check O-ring and replace it if necessary.

Only carry out steps 20 to 26 on vehicles with PDCC.
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.
Remove holder for hydraulic lines -1- on both sides.

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Holder for hydraulic lines (shown on right side)

Unscrew screws -2- .

Remove holder for hydraulic lines -1- .
Unclip hydraulic lines on the right 1 and 2- from holder -3- .

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Hydraulic lines, right
Disconnect hydraulic lines -1- from distributor

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Hydraulic lines on distributor

Unscrew union nuts -3- on hydraulic lines -1- .

Close off line connections using suitable stoppers.

Secure hydraulic lines -1- to the underbody with a tie-wrap.
Unclip hydraulic lines -1- from holders

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Holder for hydraulic lines
Disconnect plug-in couplings -1 and 2- from valve block. Collect emerging Pentosin.

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Hydraulic lines on valve block

Release pressure line -1- using an open-ended wrench (a/f 15) -2- by pressing the pressure ring -Arrow- with an open-ended wrench (a/f 15) -2- towards the valve block and then pull off the pressure line -1- .

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Pressure line on valve block
Close off hydraulic lines -1- using suitable stoppers -2- and secure with a tie-wrap -Arrow- .

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Hydraulic lines
Loosen anti-roll bar -1- from connecting link -2- .
Unscrew nut -3- and counter at joint pin on connecting link.

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Anti-roll bar - PDCC
ONLY for vehicles without PDCC:
Loosen anti-roll bar from connecting link -1- at the bottom.

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Mounting for connecting link (conventional)

Unscrew nut -2- and counter at joint pin on connecting link.
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.

Information

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

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Rear axle carrier mounting

Position > VAS 6931 - engine and gearbox jack under the rear axle carrier -1- .

Unscrew screws -2 and 3- on both sides.

Lower the rear axle carrier -1- with anti-roll bar and set it down.
Release and disconnect electric plug connections -1- .

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Electric plug connections on double clutch transmission
Disconnect B+ line.
Open cap -1- and unscrew collar nut -2- .

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Connection point for B+ line
Unscrew screw -2- and remove ground strap -1- on longitudinal member.

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Ground strap from engine to body

For all wheel drive vehicles:
Loosen cardan shaft -1- on transmission flange and tie it up with a tie-wrap -2- .
Refer to WM, 390219 REMOVING AND INSTALLING CARDAN SHAFT .

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Tying up cardan shaft
Prepare tools for lowering the engine.
> 1001IN TOOLS FOR REMOVING UNITS AND WORKING ON THE ASSEMBLY SUPPORT
Prepare engine for removal.

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Engine mounts

Support the engine using > VAS 6832 - Master Gear unit elevating platform with > 9769 - retainer plate and > 9769/1 - support .

Also secure the engine/transmission unit on the elevating platform with > 9454 - strapping belts .

Unscrew screws securing engine mount -1- to engine mount bracket on both sides.
Remove transmission support -5- and transmission bracket -3- .

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Transmission support and transmission bracket

Unscrew screws -1- and unscrew nuts -2- on transmission bracket -3- .

Unscrew nuts -4- on transmission support -5- .
Carefully lower the engine/transmission unit using > VAS 6832 - Master Gear unit elevating platform .