Part 1
Removing and installing engine
Preliminary work
Warning
Risk of injury from hot engine and hot engine fluids.
Danger of burns, scalding, damage to skin, injury to the eyes.
- Do not carry out work on the engine while it is hot.
Warning
Coolant is hazardous to health.
Risk of skin irritation.
- Wear protective gloves and goggles.
- In the event of contact with the skin or eyes, wash immediately with plenty of water.
Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
1. Raise the vehicle at the prescribed jacking points.
Danger
Vehicle raised incorrectly.
Danger of fatal injury or material damage should the vehicle fall down.
- Raise the vehicle at the prescribed jacking points.
2. Read out the fault memory using the PIWIS Tester 9718.
3. Place protective covers on the body to prevent damage.
4. Disconnect the battery and cover battery terminals or battery.
5. Remove both rear wheels. Use the prescribed special tool socket-wrench insert 300 to avoid damaging the rims.
6. Remove the rear apron.
7. Remove the side retaining frame (heat protection) at the left and right.
8. Loosen and remove support securing rear apron to body -2-.
Rear apron support
9. Remove cover for center and rear underbody.
10. Remove the complete air cleaner housing.
11. Open cap -1- on coolant reservoir.
Cap on coolant reservoir
12. Drain coolant.
12.1. Unscrew coolant drain plugs and collect emerging coolant.
12.2. Open supply and return coolant hoses at the underbody (Henn coupling). Collect emerging coolant. Grease O-rings with a light coating of Kluber Syntheso Glep and fit Henn couplings.
12.3. Open spring band clamps -2- on supply and return hoses for heating -1- and pull off hoses.
Coolant hoses for heating (shown on manual transmission)
12.4. Refit drain plugs with a new sealing ring.
- Tightening torque: 25Nm (19ftlb.)
Removing engine
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.
Warning
Coolant is hazardous to health.
Risk of skin irritation.
- Wear protective gloves and goggles.
- In the event of contact with the skin or eyes, wash immediately with plenty of water.
Caution
Danger of trapping oxygen sensor cables when lowering the engine.
Material damage.
- Place cable with connector between engine and engine strut.
Caution
Risk of material damage when lowering engine
Damaged components must be replaced.
- Get one or two more people to help.
Information
The air-conditioning lines on the compressor do not need to be disconnected in order to remove the engine/transmission unit.
Following removal, place the air conditioning compressor on a suitable protective support (e.g. foam, neoprene).
Information
If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted.
If the cross member is not refitted, the vehicle will have to be aligned after the engine is installed.
Danger
Fuel can escape when fuel line is opened.
Risk of fatal injury!
Risk of damage to skin.
- Do not work on the fuel system when the engine is hot!
- Do not smoke, avoid fire and naked flames!
- Wear fuel-resistant protective gloves and goggles.
- Attach warning sign to vehicle in a clearly visible position.
1. Before opening the fuel lines, put up or attach a warning sign in a clearly visible position on the vehicle.
Example of a warning sign
2. Open fuel line connections at the left in the engine compartment.
2.1. Open tank vent line -1-. Press locking lugs on plug-in connection and pull line apart.
2.2. Open fuel pressure line (low pressure) -2-. Press locking lugs on plug-in connection and pull line apart. Collect emerging fuel with a cloth.
2.3. Unclip fuel line from the holder on the coolant reservoir -3-.
Fuel line connections
Fuel line holder
3. Disconnect breather hose -2- on the coolant reservoir and engine supply hose -3-.
3.1. Open the two spring band clamps -1 and 4- and pull off hoses.
Coolant breather hose and engine supply hose
4. Disconnect supply hose -1- for thermostat housing.
4.1. Open spring band clamp and pull off the hose.
Coolant hose for thermostat housing
5. Pull off hose for right coolant pipe -1-.
5.1. Pull safety clip -2- on Henn coupling out of the lock and pull out coolant hose.
5.2. Close off the opening with a clean cloth or stopper. Refit safety clip immediately.
5.3. Check O-ring and replace it if necessary.
Return coolant hose for radiator
6. Pull oxygen sensor plug connections on the left and right in the engine compartment out of the holder and expose lines.
Oxygen sensor connectors, cylinder bank 1-3
Oxygen sensor connectors in engine compartment, cylinder bank 4-6
6.1. The connectors are color-coded.
7. Loosen the drive belt -1-.
7.1. Turn the tensioner -3- clockwise at the hexagon (a/f 30) using a ring wrench -2- and take off the belt.
7.2. Allow the tensioner to slide back to its initial position.
Slackening/tensioning the drive belt
8. Remove the resonance tube. This is necessary in order to remove the front fastening screw on the air conditioning compressor.
Resonance tube mounting
9. Remove positive crankcase ventilation line at the oil module and cylinder head on cylinder bank 4-6.
9.1. Unscrew M6 outer Torx screw -1- on the oil module. Loosen plug-in coupling on the cylinder head -2- by pressing the locking ring.
9.2. Pull off vent line -3- on the oil module.
Crankcase vent line connection
10. Open plug connection on control line -1- for the air conditioning compressor.
Control line for air conditioning compressor
11. Loosen air conditioning compressor. The air conditioning system remains closed.
11.1. Unscrew rear outer Torx fastening screws (M8 x 90) on the air conditioning compressor and remove with the holder.
11.2. Unscrew the front outer Torx fastening screw (M8 x 120) on the air conditioning compressor.
12. Lift the air conditioning compressor with the connected lines out of the mount and place them on a protective support. Secure with a tie-wrap if necessary.
13. Loosen engine wire harness at the connector console at the right in the engine compartment.
13.1. Open the bayonet locks -1- on three round connectors by turning anti-clockwise and pull off connectors.
Engine wire harness connection
13.2. Cut through the tie-wrap at the cable guide -arrow- and lay the wire harness on the engine.
Engine wire harness fastening
14. Open plug-in couplings for the steering and clutch hydraulics on the underbody. Collect emerging Pentosin in a suitable container.
Plug-in coupling (steering and clutch hydraulics)
14.1. Re-connect lines immediately after draining them.
Information
When opening the power-steering oil lines, make sure that Pentosin does not drop onto the rubber sleeves of the fuel injectors.
Cover this area beforehand with a cloth.
If drops of Pentosin fall onto a rubber sleeve, clean it immediately.
Replace swollen rubber sleeves.
15. Open the pressure and return lines for power steering in the engine compartment.
15.1. Remove remaining fluid from the power-steering oil tank using suction.
15.2. Always place a clean cloth under the line connections and have a small container ready. After opening the line connections, collect emerging Pentosin with the container.
Collecting Pentosin
15.3. Open the pressure line using loosening tool 9780.
Special tool 9780
Releasing plug-in coupling (as of model year 2009)
15.4. Loosen the spring band clamp on the return line.
16. Close off power-steering lines and secure to the rear lid hinge with a tie-wrap.
17. Loosen drive shafts on the transmission.
Drive shaft for manual transmission
17.1. In the rear axle area, slide a suitable protector (e.g. an old coolant hose) over the shaft or place a piece of plastic foam underneath it.
17.2. Counter using special tool adapter plate 9510/1 -1-.
Retaining tool for drive-shaft bolts
18. Loosen ground cable for the engine -1- on the longitudinal member. Screw off M8 hexagon nut -2- and remove cable eyelet from the threaded bolt.
Engine ground cable
19. Remove the rear anti-roll bar.
19.1. Unscrew two M8 x 40 hexagon-head bolts -1- at the left and right.
19.2. Loosen one M10 hexagon nut -2- on the connecting link and counter at the inner Torx screw on the connecting link while doing this.
19.3. Remove the anti-roll bar.
Rear anti-roll bar mount
20. Remove transverse strut -1- and the two diagonal braces -3-.
20.1. Front transverse strut: Unscrew two hexagon-head bolts (M10 x 40) -2-.
20.2. Remove threaded connections for diagonal braces -4-: two M12 x 30 hexagon-head bolts on the rear cross member, two M10 x 40 hexagon-head bolts at the front and two M10 hexagon nuts on the rubber mountings.
Diagonal brace and transverse strut
21. Remove the rear cross member.
21.1. Bottom mounting: Screw off two M12 hexagon nuts, counter at the M12 x 80 hexagon-head bolts, remove both screws from the bores.
21.2. Top mounting -arrow-: Loosen two M12 hexagon nuts (slots in cross member), remove cross member by pulling it downwards.
21.3. Remove screw and nut at the left in direction of travel because otherwise the cylinder head on cylinder bank 1-3 can be damaged when the engine is lowered.
Top mounting on rear cross member
22. Loosen B+ lines on the transmission.
22.1. PDK: Open the lid of the plastic box -1-, screw off the M8 hexagon nut -2- and remove the lines -3 and 4-.
B+ connection on PDK transmission