Part 2
Removing and installing engine (continued)
22.2. Manual transmission:
B+ connection on manual transmission
PDK transmission:
23. Remove parking lock cable.
23.1. Press end piece of cable -1- off the ball head of the parking lock lever using disassembly tool Nr.21 -2-.
Pressing off parking lock cable on PDK transmission
23.2. Unclip cable -1- from the guide.
Unclipping parking lock cable
To do this, press the two locking clips -2- together and pull the cable out of the guide.
Cable lock
23.3. Loosen two cable connectors for the PDK transmission. Open the bayonet locks on the connectors -1- by turning them anticlockwise.
Top PDK connector
Unclip cable guide on the transmission -2-.
Bottom PDK connector (locked) with cable guide
23.4. Disconnect cable plug -1- for disc valve control (PDK only).
Cable plug for disc valve control
Manual transmission:
24. Disengage shift and selector cables -1-.
Shift and selector cable connection on manual transmission
Press the locking clip together and pull each cable out of the guide.
Removing shift and selector cables
25. Manual transmission: Pull off connector for reversing light switch.
Electric plug for reversing light switch
26. Pull off vacuum line -1- for brake booster.
Brake booster vacuum line
Alldata editors note:
A. Only for All-Wheel Drive Vehicles: Remove cardan shaft.
B. Pull cardan shaft out of the front-axle final drive and set it aside.
Cardan shaft threaded joint
27. Loosen transmission bracket -1-.
27.1. Loosen four M10 hexagon nuts (squeeze-lock nuts) -2-, then loosen the M12 outer Torx screw -3- on the transmission mount. Counter at the outer Torx nut while doing this.
Transmission bracket
28. Master Gear unit elevating platform WE 1206 must be ready for removing the engine.
28.1. Observe installation position.
Master Gear unit elevating platform with mounting point for engine and transmission support, 997
1 - Master Gear unit elevating platform WE 1206
2 - Support 9769/1 for PDK transmission
3 - Support 9769/2 for manual transmission
4 - Retainer plate 9769 for engine
29. Move the elevating platform -1- under the vehicle. Position the supports -2- of the retainer plate 9769 on the engine.
Supporting engine with a unit lifting platform
Mounting points -arrows- for the retainer plate supports.
Engine mounting points
29.1. The tilt angle of the lifting platform plate -3- can be changed as required to suit the installation position of the engine/transmission unit.
29.2. Position the required transmission bracket under the transmission.
29.3. Support the engine/transmission unit slightly with the lifting platform.
30. For safety reasons, the engine must also be secured on the lifting platform by fastening a tension strap -1- (e.g. strapping belt 9454) at the exhaust manifold -arrows-.
Tension strap on exhaust manifold, cylinder bank 1-3
Tension strap on exhaust manifold, cylinder bank 4-6
31. Loosen and screw off two M12 inner Torx nuts (screwdriver insert T55) on the engine carrier.
Engine carrier to engine mounting (view of cylinder bank 4-6)
31.1. Remove the transmission bracket. Unscrew four M10 hexagon nuts and one M12 outer Torx screw on the transmission mount and remove the bracket.
31.2. Pull off plastic holder -2- for coolant pipes and coolant vent line.
Holder for coolant pipes and coolant vent line
32. Slowly lower the engine/transmission unit with the lifting platform.
Additional work for manual transmission:
- Remove pressure and return lines on the clutch slave cylinder.
Place a clean cloth under the clutch cylinder to collect emerging fluid.
-1. Loosen the rapid-action coupling -3- on the return line -1- by pressing the locking buttons -arrows- and pull off the line.
Releasing plug-in coupling on return line
-2. Screw off pressure line, unclip it and let it hang to one side. Close off the line with a stopper and secure with a tie wrap if necessary.
-3. Watch out for the lines when lowering the engine/transmission unit.
33. Completely lower the engine/transmission unit with the lifting platform.
Information
Check to see if spacers are fitted on cylinder head side 4-6 (relates to all-wheel drive vehicles).
These must be converted when replacing the engine.
Replace damaged spacers.
34. Only for all-wheel drive vehicles: Check that the spacer -1- is fitted on cylinder head side 4-6.
34.1. If you are replacing engine, remove the spacers and fit them on the new engine.
Spacers on all-wheel drive vehicles.
Installing engine
Caution
Risk of damage when inserting the engine/transmission unit into the vehicle
Material damage!
- Enlist assistance of second and, if necessary, third person.
Information
Check to see if spacers are fitted on cylinder head side 4-6 (relates to all-wheel drive vehicles).
These must be converted when replacing the engine.
Replace damaged spacers.
1. Only for all-wheel drive vehicles: Check that the spacer -1- is fitted on cylinder head side 4-6.
1.1 Secure the spacer on a new engine using two screws -2-. - Tightening Torque: 13 Nm (9.5 ftlb.)
Spacers on all-wheel drive vehicles
For manual transmission only:
2. Raise the engine/transmission unit approximately halfway using the Master Gear unit lifting platform WE 1206.
3. Fit pressure and return lines on the clutch slave cylinder.
3.1. Fit the pressure line.
- Tightening torque: 20 Nm (15 ftlb.)
3.2. Connect the return line -1-.
Fitting return line
Manual transmission and PDK:
4. Move engine/transmission unit into installation position and secure the unit mounts.
Alldata editors note:
4a. Only for All-Wheel Drive Vehicles:: Install cardan shaft.
Cardan shaft threaded joint
4b. Fit four M10 hexagon nuts and two M10 x 55 hexagon-head bolts -arrows- on the transmission bracket and tighten them.
- Tightening torque: 65 Nm (48 ftlb.)
4.1. Fit and tighten M10 collar nuts -2- on the transmission bracket -1- and M12 outer Torx screw -3- for the transmission mount.
Transmission bracket
- Tightening torque: 65 Nm (48 ftlb.)
- Tightening torque: 120 Nm (89 ftlb.)
4.2. Fit and tighten M12 inner Torx nuts (screwdriver insert T55) on the engine carrier.
Engine carrier to engine mounting (view of cylinder bank 4-6)
- Tightening torque: 85 Nm (63 ftlb.)
5. Loosen tension straps and move Master Gear unit elevating platform WE 1206 out of the work area.
PDK transmission:
6. Plug in PDK connector. The connectors and housing must be locked together so that the relevant connector can be plugged in.
6.1. Check locking position of the connector -2- in the connector housing -1-. The small lug -3- must be touching the connector housing so that the position is aligned with the arrow marking on the housing.
Locking position of PDK connector
If the connector is not locked, turn it clockwise as far as it will go.
Locking PDK connector
6.2. Plug in PDK connector (arrows -1- must be aligned).
Locking position not locked
6.3. Close bayonet locks by turning them clockwise. Then clip in cable guide on the transmission -2-.
Bottom PDK connector (locked) with cable guide
6.4. Disconnect cable plug -1- for disc valve control.
Cable plug for disc valve control
7. PDK: Fit parking lock cable.
8. Fit B+ lines on the transmission.
8.1. PDK: Insert lines -3 and 4- and fit and tighten M8 hexagon nut -2-. Close the lid.
B+ connection on PDK transmission
8.2. Manual transmission:
B+ connection on manual transmission
8.3. - Tightening torque: 23 Nm (17 ftlb.)
Manual transmission:
9. Fit shift and selector cables.
Shift cables for manual transmission
Connecting shift cable:
Connecting shift cable for manual transmission
10. Manual transmission: Plug in cable plug for reversing light switch.
Electric plug for reversing light switch
11. Secure ground cable for engine on the body -arrow-.
- Tightening torque: 23 Nm (17 ftlb.)
Engine ground strap
12. Secure the drive shafts on the transmission flange.
- Tightening torque: 81 Nm (60 ftlb.)
13. Install chassis components:
13.1. Rear cross member -C-: hexagon-head bolts and M12 collar nuts.
- Tightening torque: 110 Nm (81.5 ftlb.)
13.2. Diagonal braces -B- to rear cross member: M12 hexagon-head bolt.
- Tightening torque: 110 Nm (81.5 ftlb.)
13.3. Diagonal brace -B- to rear axle carrier: M10 collar nut.
- Tightening torque: 23 Nm (17 ftlb.)
13.4. Diagonal brace -B- to body: M10 hexagon-head bolt.
- Tightening torque: 65 Nm (48 ftlb.)
13.5. Transverse strut -A- to body: M10 hexagon-head bolt.
- Tightening torque: 65 Nm (48 ftlb.)
Cross member with accessories
14. Install rear anti-roll bar.
14.1. Engage anti-roll baron the connecting links and then secure on the rear axle carrier using two hexagon-head bolts on each -1-.
Rear anti-roll bar mount
- Tightening torque: 23 Nm (17 ftlb.)
14.2. Fit new M10 collar nuts on the connecting link joint -2-. Counter with a Torx socket-wrench insert when tightening.
- Initial tightening torque: 50 Nm (37 ftlb.)
Anti-roll bar to connecting link
14.3. Loosen collar nuts by 90° and then tighten them again.
- Final tightening torque: 65 Nm (48 ftlb.)
15. Fit power-steering lines.
15.1. Connect the pressure line.
15.2. Fit the return hose on the line using the spring band clamp.
16. Fit engine wire harness.
Engine wire harness connection
1 - Blue ring
2 - Grey ring
3 - Black ring
16.1. Turn the bayonet lock clockwise as far as it will go.
16.2. Secure the wire harness to the holder with anew tie-wrap -arrow-.
17. Fit air conditioning compressor.
1 - Outer Torx screw, M8 x 90
2 - Holder
Air conditioning compressor mounting
3 - Outer Torx screw, M8 x 170
17.1. Screw in rear screws -1- with holder -2-.
17.2. Screw in front screws -3-.
17.3. Tighten fastening screws to the specified torque.
- Tightening torque: 23 Nm (17 ftlb.)
Control line for air conditioning compressor
17.4. Connect cable plug for control line -1-.
18. Fit the drive belt. Pay attention to operating direction of used belts.
Slackening/tensioning the drive belt
18.1. Check once again that the drive belt is positioned correctly on the pulleys.
19. Fit the resonance tube.
20. Fit oxygen sensor plug connections at the left and right in the engine compartment, route the lines and secure them at the retaining points -arrows-.
Oxygen sensor connectors, cylinder bank 1-3
Oxygen sensor connectors, cylinder bank 4-6
20.1. The connectors and cables are color-coded.
Information
Check Henn coupling O-rings and replace them if necessary.
Clean plug connection and coolant hoses before assembly.
Coat O-rings and coolant hoses with KIuberplus Gel (Part No. 000.043.205.93).
Remove stoppers before fitting the coolant lines and hoses.
21. Fit hose for the right coolant pipe -1-.
21.1. Lightly grease the O-ring.
21.2. Check the position of the safety clip -2- and connect the coolant hose.
Return coolant hose for radiator
22. Fit the supply hose -1- to the thermostat housing.
22.1. Lightly grease the inside of the hose.
22.2. Slide on the hose and close the spring band clamp -2-.
Coolant hose for thermostat housing
23. Fit the breather hose -2- on the coolant reservoir and engine supply hose -3-.
23.1. Lightly grease the inside of the hoses.
23.2. Slide on the two hoses and close the spring band clamps -1 and 4-.
Coolant breather hose and engine supply hose
24. Connect fuel line connections at the left in the engine compartment.
24.1. Connect fuel tank ventilation line -1-.
24.2. Connect fuel pressure line (low pressure) -2-.
Fuel line connections
24.3. Pull to check that the lines are secure.
24.4. Clip fuel line -2- into the holder -1-.
Fuel line holder
Subsequent work
Information
Check Henn coupling O-rings and replace them if necessary.
Clean plug connection and coolant hoses before assembly.
Coat O-rings and coolant hoses with KIuberplus Gel (Part No. 000.043.205.93).
Remove stoppers before fitting the coolant lines and hoses.
1. Fill in coolant and bleed the cooling system.
2. Fit support for rear apron on the body using an M6 hexagon-head bolt -2-, but do not tighten the bolt until you have fitted the rear apron.
Rear apron support
- Tightening torque: 10 Nm (7.5 ftlb.)
3. Install side retaining frame (heat protection) for the rear apron.
4. Install rear apron.
5. Fit rear wheels. Use special tool socket-wrench insert 300 to tighten the wheel bolts.
- Tightening torque: 130 Nm (96 ftlb.)
6. Connect the battery.
7. Check engine-oil level and top up with new engine oil if necessary.
8. Heat the engine to operating temperature and check the coolant level again.
8.1. Check all connections on the cooling system that were opened during removal for leaks.
9. Fill in Pentosin in the power-steering oil tank, check the fluid level and top it up if necessary.
10. Remove protective covers.