Part 1
WM 100119 Removing and installing 3.6-litre DFI engine
Tools
Technical values
Preliminary work
Special equipment-specific features are described in the notes.
1. Position the vehicle at the take-up points provided on a lifting platform. => Lifting the vehicle
2. Fix steering wheel with wheels in straight-ahead position (engage steering column lock or clamp steering wheel in centre position with steering wheel holder)! If this is not done, the airbag contact unit will have to be put in centre position after installation of the steering gear! -> 945019 Removing and installing steering-column switch Service and Repair
3. Put on the protection covers.
4. Read out the DME fault memory. Write down or print the result. -> 0101IN00 Diagnostic system: reading out fault memory and activating systems Testing and Inspection
5. Move the Tiptronic selector lever to position N.
6. Remove ignition key.
7. Disconnect the battery. -> 9000IN00 Work instructions after disconnecting the battery
8. Remove front wheels. -> 44051900 Removing and installing wheel - section on "Removing" Removal and Replacement
9. Remove the front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Removing" Service and Repair
10. Remove engine guard with transverse strut. -> 108019 Removing and installing engine guard (underbody panel) - section on "Removing" 108019 Removing and installing engine guard (underbody panelling)
11. Drain coolant. -> 193817 Draining and filling in coolant on DFI engines (includes bleeding) - section on "Draining" Service and Repair
12. Remove engine compartment covers. -> 700219 Removing and installing front cover (engine compartment) - section on "Removing"
13. Move bonnet into service position -> 553119 Removing and installing front gas spring Service and Repair. While doing this, remove engine compartment rubber seal -> 553319 Removing and installing front lid seal - section on "Removing" Service and Repair.
14. Remove cover of plenum panel. -> 664419 Removing and installing cowl panel cover - section on "Removing" Service and Repair
15. Remove intake pipe. -> 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Removing" Service and Repair
16. Remove air cleaner housing cover and filter element.
Information
- The air tube is only present in vehicles with air suspension.
16.1. Remove air tube on air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the notch in the cap and lever the cap off.
Cap on air tube
16.2. Push the circlip into the adapter -1- and pull it off together with the adapter -2-.
Circlip
16.3. Clip the green cap on again after disassembly.
Cap
16.4. Remove air cleaner cover. Undo the fastening clamps on the air cleaner housing. Pull air cleaner cover up and out.
Fastening clamps on air cleaning housings
16.5. Remove air-cleaner element.
17. On vehicles with manual transmission, work on peripheral units must be performed as described in -> 343519 Removing and installing transmission - section on "Removing" 343519 Removing and installing transmission.
Tools and materials
Tools
Tool setup - Master Gear unit elevating platform WE 1206 with suitable setup kit.
Lifting platform
Tool overview
Complete structure of the base carrier with mounting mandrels
Removing engine
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 vapours.
-> Attach warning sign in a clearly visible position.
WARNING
Caustic fluids
- 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.
NOTICE
Aggressive fluids
- Risk of damage to components and surfaces
-> Do not spill fluids.
-> In the event of contact, wash the component or surface with water.
-> Replace components that are already damaged.
Information
The slightly different illustrations between V8 and V6 show essentially the same actions.
Information
When lowering the engine, make sure that cables or lines are not trapped accidentally between the engine and body. To prevent this, a second person must make sure that the cables and lines do not get caught.
1. Disconnect the engine wiring harness on the right-hand side of the vehicle. To do this, unclip, lift and disconnect the control unit. Disconnect the ground point. -arrows-
Engine wiring harness
2. Open the cover on the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws. -arrows-
Torx screws for cover of central electrical system
3. Disconnect the two connectors for the engine wiring harness (white, red) inside the central electrical system. Undo the wiring harness from the retaining clips inside the plenum panel, remove it and lay it down on the engine. => Cable plug for engine wiring harness
Cable plug for engine wiring harness
4. Disconnect B+ transfer point at the left of the engine compartment. To do this, disconnect the two connecting cables -A and B- for the engine. Unclip B+ cable -B- out of the plastic holder at the bulkhead.
B+ transfer point
5. Disconnect the two coolant lines and the vacuum line on the right side of the engine compartment. -1 to 3- Simply pull off vacuum line (hold line securely below the connection).
Wiring
6. Disconnect the four oxygen sensor connectors (brown, black) at the body next to the spring strut dome on the right and unclip the cables from the supports. -1, 2, 3, and 4-
Oxygen sensor connector next to spring-strut dome
7. Empty the servo oil reservoir with a syringe. Then remove the hose from the reservoir. Close the open connections with plugs. => Servo oil reservoir
Servo oil reservoir
8. Disconnect fuel line -1- and tank vent line from the carbon canister -2- at the plenum panel splash panel. Unclip tank vent line at the plenum panel
Tank vent and fuel line
9. Loosen the three fastening screws for the spring struts at the left and right -1-. The screws are loosened from inside the engine compartment. Of the three screws per spring strut, one is in the plenum panel. The screws must not be re-used.
Spring strut threaded joint
10. Disconnect the coolant supply and return lines from the radiator. To do this, pull out the securing clip at the upper hose and pull off the connection -1-. The clip should be fitted again immediately to avoid confusion. Undo bottom hose -2-. To do this, undo spring band clamp and pull off hose.
Coolant hoses
Information
- The drive belt must be slackened so that the air-conditioning compressor can be removed later.
- If at all possible, the air-conditioning system should not be opened.
11. Slacken the drive belt. To do this, screw a screw (M8 x 50) into the tensioner until the belt can be removed from the tensioning roller. => Drive belt
Drive belt
Information
- In the case of vehicles with air suspension, the compressed air line on the spring strut must also be disconnected. Loosen the line carefully and allow the remaining pressure to escape. Loosen the threaded joint completely only when the line is fully depressurised.
Compressed air line on spring strut
- The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.
Electric plug connection for height sensor
12. Disconnect electric connector for the wear indicator -1-. Then unclip the supports -2 and 3-. Expose the cable. Disconnect and expose cable for ABS sensor => Cable guide at spring strut 1.
Cable guide at spring strut 1
Cable guide at spring strut 2
13. Disconnect the brake lines in the wheel housings to the left and right. => Brake lines in wheel housings
Brake lines in wheel housings
14. Disconnect the ground point on the right side member. -arrow-
Ground point on right side member
15. Disconnect the ATF lines on the ATF thermostat => ATF lines on radiator. To do this, loosen the fastening screw (a/f 10) and pull the lines off. Seal open lines with plugs.
ATF lines on radiator
16. Disconnect the electric plug on the steering gear (Servotronic only). -arrow- Figure shows right-hand drive vehicle.
Servotronic cable plug
17. Remove the heat shield on the steering gear connection. To do this, loosen the two fastening screws -1 - figure shows right-hand drive vehicle-.
Heat shield for steering gear
18. Loosen the clamping screw from the steering column on the steering gear and remove it -2-. The screw must not be re-used. Force the steering column up and off the steering gear.
19. Disconnect coolant hoses from the coolant pipes on the transmission => Coolant hoses on transmission. Approx. two litres of coolant will flow out when you do this. Close off coolant hoses.
Coolant hoses on transmission
20. Detach exhaust system at the connection point between the centre silencer and the catalytic converters. To do this, undo both clamps -1- and push toward the centre silencer. Replace clamps.
Exhaust system
21. Detach exhaust system for the engine at the body -2 and 3-.
22. Remove rear cardan shaft -> 393519 Removing and installing rear cardan shaft 393519 Removing and installing rear cardan shaft.
23. Detach heat shield on the right of the transmission. To do this, unscrew three fastening screws -arrows-.
Heat shield
24. Disconnect electric connections -1, 2 and 3- on the transmission.
Electric connections on the transmission
25. Detach heat shield via the cable plugs on the transfer box and disconnect cable plugs. => Connections on transfer box
Connections on transfer box
26. Detach the selector lever cable on the transmission. To do this, press the ball socket away from the transmission. Then pull out top sheetmetal clip -A- and remove the cable in an upward direction. -B- must not be loosened.
Selector lever cable on the transmission
27. Disconnect the lower line on the servo oil cooler. => Lower line on servo oil cooler Close off line.
Lower line on servo oil cooler
28. Mark the installation position of the front-axle carrier diagonally on at least two places on the body using a felt-tip pen. This makes it easier to correctly position the front-axle carrier on the body during reinstallation.
Mark installation position of the front-axle carrier
Information
- Because of the high loosening torque, the six fastening screws on the front-axle carrier can already be loosened now. Loosen the screws by a maximum of one turn.
29. Place the lifting platform under the engine and raise it. When you do this, ensure that the positioning guides of the lifting platform are inserted into the body. => Lifting platform under engine
Lifting platform under engine
30. The -arrows- show the mounting points for the mounting frame in the front-axle carrier (view from below here).
Mounting points for front-axle carrier
31. Position lifting platform in the front-axle carrier in the mounting points provided -(arrows)- , -4 into the body-.
Lifting platform
32. Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckles. Then tighten the retaining brackets on the wheel hub and lifting platform. -arrow-
Securing the spring struts
33. Loosen transmission cross member. To do this, loosen the four fastening screws -A-.
Fastening screws for transmission cross member
34. Secure the engine/transmission unit. Then secure the mounting mandrels on the engine transverse bar with the locking screws.
35. Loosen the four fastening screws on the front-axle carrier and the two fastening screws on the engine transverse bar. => Fastening screws for front-axle carrier and fastening screws for engine transverse bar (centre)
Fastening screws for front-axle carrier and fastening screws for engine transverse bar (centre)
36. Lower the lifting platform slowly by approx. 20 to 30 cm. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and spring struts in the wheel housings.
Information
- It is easier to remove the air-conditioning compressor from its installation position when the engine has already been lowered a little.
- The air-conditioning compressor lines must not be kinked or twisted.
37. Loosen power-steering pump. To do this, loosen the two front fastening screws and turn the belt pulley as required -A 2-. Then loosen the rear fastening screw. -1-
Removing hydraulic pump
38. Loosen the three fastening screws and disconnect the electric connector from the air-conditioning compressor. Set the air-conditioning compressor aside. => Fastening screws and electric connector for the air-conditioning compressor
Fastening screws and electric connector for the air-conditioning compressor
39. The air-conditioning compressor must be secured with a piece of wire. => Air-conditioning compressor
Air-conditioning compressor
Information
- Before moving the lifting platform, mark the position of the wheels on the workshop floor with a piece of chalk. This makes it easier to position the platform again for re-installation.
40. Lower the lifting platform fully. When doing this, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.