Removing and Installing Engine
Removing and installing engine
Preliminary work
Danger
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 take-up points provided.
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.
2. Read out the fault memory using the PIWIS Tester 9718.
3. Place protective covers on the body to prevent damage.
4. Open lid on coolant reservoir.
Cap on coolant reservoir
5. Remove pressure pipe -1-.
Mount for pressure pipe
6. Remove air cleaner housing.
7. Disconnect the battery and cover the terminals or battery.
8. Remove both rear wheels. Use the specified special tool socket-wrench insert 300 to avoid damage to the wheel rims.
9. Remove underbody cover at the rear and center.
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
10. Drain coolant.
Coolant drain plug
11. Open the large coolant hoses on the coolant pipes. Unclip spring clamps and pull the hoses off slowly.
Henn coupling on coolant hose
12. Disconnect coolant hoses for heating. Then open the spring band clamps and pull off the hoses.
Coolant hoses for heating
13. Remove tailpipe covers.
Removing engine
Caution
Hot components
^ Risk of burns
- Let hot components cool down.
- Wear personal protective gear.
Notice
Pressure accumulator removed incorrectly
^ Damage to hoses and wiring
- First relieve pressure in the clutch system.
- Actuate the clutch pedal at least 25 times for this purpose.
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.
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.
1. Before opening the fuel lines, place a warning sign in a clearly visible position on the vehicle.
Symbolic representation of warning sign
2. Loosen union nuts (a/f 17) for fuel lines -1 and 2- at the fuel cooler. Always counter with an open-ended wrench (a/f 14) while doing this. Soak up emerging fuel with a cloth.
Fuel cooler connections
3. Mark the rolling direction of the drive belt (with a paint marker, for example). Check the drive belt and pulleys for signs of damage.
4. Relieve drive belt and remove from the pulleys.
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.
5. Open hydraulic line for power steering. Drain the line and close the threaded connection again.
Power-steering line
6. Disconnect hydraulic line with plug-in coupling at the reservoir.
6.1. Disassembly tool Nr.21 must be inserted between the line and the red circlip in order to release it by pulling the black line to the right, while at the same time pressing the tool against the red circlip.
Power-steering line on tank
Removing hydraulic line
7. Remove throttle housing. Unscrew four M6 fastening screws -arrows- and remove cable plug for electronic accelerator.
7.1. Replace seal.
Throttle housing
8. Open rapid-action couplings for fuel supply -1, 2 and 3- in left of engine compartment. Press release buttons and simultaneously pull off the line.
8.1. Soak up emerging fuel with a cloth.
Fuel line connections
9. Disconnect vacuum line for the brake booster.
10. Disconnect breather hose -4- on the coolant reservoir. Open spring band clamp -3- and pull off the hose.
Fuel lines, coolant ventilation, brake booster vacuum line
11. Open supply hose from coolant reservoir -3- and large coolant hose (Henn coupling) -2- on the left. Loosen spring band clamp -4- and spring clamp -1- and pull off hoses.
Coolant supply hose and left Henn coupling
12. Open large coolant hose (Henn coupling) on the right. Loosen spring clamp and pull off hose.
13. Disconnect the air conditioning compressor. The air conditioning system must not be opened in order to do this.
14. Place air conditioning compressor at the body/engine compartment on a solid base with the connected hoses.
15. Disconnect engine wire harness (2 round connectors with bayonet locks) from the plug connections in the right of the engine compartment. To do this, open the bayonet locks by turning them anti-clockwise.
Round connectors on engine wire harness
16. Open tie-wrap -arrow- on the cable guide for the engine wire harness and lay wire harness on the engine.
Engine wire harness attachment point
17. Open oxygen-sensor plug connections and connector strip for exhaust temperature sensor.
Connector for oxygen sensor and exhaust temperature sensor
18. Remove anti-roll bar. Unscrew two fastening screws -1- and a hexagon nut -2- at the left and right. Counter at the collar nut with a Torx insert.
Rear anti-roll bar mount
19. Remove front cross member -A- and the two diagonal braces -B-.
Removing running gear braces
Information
^ Remove upper hexagon-head bolts for the cross member so as to avoid damaging the reference mark sender cable and oil tank when lowering the engine/transmission unit.
20. Remove the rear cross member -C-. Screw off four fastening nuts -arrows (C)- and counter at the screws while doing so. Pull out lower screws and remove bracket, then take out the upper screws. U-profiles are used for the threaded joints on the bracket to make disassembly/assembly easier.
Cross member mount, top
21. Fit drain plugs with new sealing rings on the coolant pipes and tighten them. - Tightening torque: 10 Nm (7.5 ftlb.)+5 Nm (+3.5 ftlb.)
Coolant drain plug
22. Fit special tool adapter plate 9510/1 -1- to the wheel mount on the brake disc in order to counter when loosening the drive-shaft bolts.
Retaining tool for drive-shaft bolts
23. Loosen drive-shaft bolts on the transmission side. To protect the coating, wrap a cloth around the shafts and place them on the axle support.
24. Pull off cable plug for reversing light on transmission.
24.1. If the locking clip on the cable plug cannot be pressed (switch screw-in position), the switch must be loosened.
Cable plug for reversing light switch
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
Warning
Caustic fluid
^ Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
25. Loosen the coolant hoses on the transmission. Open spring band clamps and pull off hoses. Collect emerging coolant.
Coolant hoses (shown on manual transmission)
26. Screw out four M10 hexagon nuts and two M10 x 55 hexagon-head bolts -arrows- on the transmission bracket and remove bracket.
Bolts on transmission bracket
27. 997 Turbo only: Remove cardan shaft.
27.1. Pull cardan shaft out of the front-axle final drive and set it aside.
Cardan shaft threaded joint
28. Disengage shift cables.
29. Loosen electric connection lines on the starter. To do this, remove the protection cap on the solenoid switch and unscrew and remove the fastening nuts on the line for terminal 30 -1-, terminal 50 -2- on the starter.
Protection cap on solenoid switch and electric connections on the starter (shown on manual transmission)
Information
Check for cuts on the entire diameter of the inner rubber edge on the suction hose leading to the turbocharger. Replace if damaged.
30. Loosen the intake air lines on the turbochargers. Open the screw-type clamp -1- and pull off the line -2-.
Intake air line on turbocharger
31. Disconnect engine ground strap on the body. Screw off hexagon nut -1- and remove cable -2-.
Engine ground strap
32. Open clutch pressure line.
32.1. Loosen threaded connection -A- -make sure to counter with an open-ended wrench when doing this -B-. Collect emerging hydraulic fluid and close off the lines.
Opening clutch pressure line
33. Remove crash support. Re-fit nuts and bolts immediately after removal (joint!). - Tightening torque: 23 Nm (17 ftlb.)
Crash support
34. Prepare lifting platform and use the following special tools for removal: Secure the mounting plates on each side using two nuts and bolts -2- at the position shown (observe hole pattern on lifting platform).
Engine retainer plate 9111/3
Adapter 9111 /1
Spacer 9111/4
Spacer 9111/5
Additional support 9111/6
Engine retainer plate on lifting platform
35. Position lifting platform with pre-fitted engine retainer plate slightly tensioned on the engine. The spacer 9111/5 must be locked in a horizontal position.
Support 911115 for engine retainer plate
36. Loosen collar nuts on transmission bracket.
37. Loosen collar nuts on engine carrier from the engine mounts (wrench size 18).
Notice
Engine/transmission unit lowered or inserted incorrectly
^ Risk of damage to engine/transmission unit
^ Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Information
^ Get a second person to check the clearance when lowering the engine/transmission unit.
^ If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted in order to maintain structural strength.
38. Lower the engine/transmission unit carefully and in steps.
Lifting platform under the vehicle
Installing 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.
Information
^ The engine/transmission unit is essentially installed in reverse order to removal.
^ First complete the fluid systems opened during removal.
Information
^ Get a second person to check the engine/transmission clearance when lifting it.
^ Pay particular attention to the clearance between rear-axle cross member and oil tank.
1. Lift the engine-transmission unit carefully and in steps.
2. Tighten M12 collar nuts on the engine mounting. - Tightening torque: 85 Nm (63 ftlb.)
3. Fit M10 collar nuts on transmission support. - Tightening torque: 65 Nm (48 ftlb.)
4. Lift the vehicle and move lifting platform out of the work area.
5. Fit crash support. Spray fastening screws with Loctite 574 and tighten them. - Tightening torque: 23 Nm (17 ftlb.)
Crash support
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 Kluberplus Gel (Part No. 000.043.205.93).
^ Remove stoppers before fitting the coolant lines and hoses.
6. Remove stoppers from the coolant lines before fitting.
Information
To facilitate assembly of coolant pipes and hoses, smear with Kluber Syntheso Glep or alternatively Kluberplus S06-100 assembly gel.
Information
^ The coolant hoses must engage audibly when pushed into the flanges (Henn coupling).
7. Engage spring clamps -1- on the coolant pipes and insert large coolant hoses -2-. Pull to check that the hoses are secure.
Henn coupling on coolant hose
8. Fit coolant hoses for heating.
Coolant hoses for heating
9. Fit coolant hoses on the transmission.
9.1. On Tiptronic vehicles, fit additional hose on the disc valve.
Coolant hoses (shown on manual transmission)
10. Fit clutch line.
- Tightening torque: 30 Nm (22 ftlb.)
11. Secure engine ground strap to the body.
- Tightening torque: 23 Nm (117 ftlb.)
Engine ground strap
12. Fit electric connections (B+ cable) on the starter.
13. Fit shift and selector cables.
14. Fit drive shafts.
- Tightening torque: 81 Nm (60 ftlb.)
- Tightening torque: 90 Nm (67 ftlb.)
15. Fit power-steering lines.
Power-steering line on tank
Connecting power-steering pressure pipe
Information
Listen for a clearly audible locking sound when fitting all rapid-action coupling connections and cable plugs. Pull to check that connections are secure.
16. Fit rapid-action couplings on fuel lines and make sure they lock with a clearly audible locking sound.
16.1. Clip fuel lines securely into the holders provided to prevent leaks.
Fuel line connections
17. Push on vacuum line for the brake booster and fit plastic snap ring.
18. Fit coolant vent line -4- on the coolant reservoir and supply line for the coolant pump.
Left engine compartment lines
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 Kluberplus Gel (Part No. 000.043.205.93).
^ Remove stoppers before fitting the coolant lines and hoses.
19. Fit large coolant lines in engine compartment.
19.1. Check O-rings on the Henn couplings and replace them if necessary.
19.2. First insert the spring clamps, then the couplings. These must lock into place with a clearly audible click.
20. Fit two connectors for the engine wire harness.
The round connectors are color-coded on the inside.
- Upper round connector - black
- Lower round connector - grey
Round connectors on engine wire harness
21. Fit new tie-wrap for securing the engine wire harness on the plastic holder.
Engine wire harness attachment point
22. Route oxygen sensor cable and exhaust temperature sensor cable carefully and attach connections.
Connector for oxygen sensor and exhaust temperature sensor
23. Be careful with the spacer sleeve for the air conditioning compressor.
Spacer sleeve on air conditioning compressor threaded joint
24. Fit air conditioning compressor.
Information
^ Observe sequence for fitting the drive belt.
25. Fit drive belt.
26. 997 Turbo only: Install cardan shaft.
Cardan shaft threaded joint
27. 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.)
Threaded joint on transmission bracket
28. Fit rear-axle carrier. Position and tighten four screws and collar nuts.
- Tightening torque: 110 Nm (81.5 ftlb.)
29. Fit transverse struts and diagonal braces.
- Tightening torque: 65 Nm (48 ftlb.)
- Tightening torque: 65 Nm (48 ftlb.)
- Tightening torque: 110 Nm (81.5 ftlb.)
Subsequent work
1. Fit tailpipe covers.
- Tightening torque: 30 Nm (22 ftlb.)
2. Install air cleaner housing.
3. Install pressure pipe.
4. Fill in coolant and bleed the system.
5. Bleed the clutch system.
6. Connect the battery.
7. Heat the engine to operating temperature and check the coolant level again. Check all connections on the cooling system that were opened during removal for leaks.
8. Check fluid level (Pentosin) in power-steering system and top it up if necessary.
9. Check engine-oil level and top up if necessary.
10. Mount rear wheels. Use the prescribed special tool socket-wrench insert 300 to avoid damaging the rims.
- Tightening torque: 130 Nm (96 ftlb.)
11. Fit rear and center underbody cover.
12. Remove protective covers on body.
13. Perform a test drive.