11 00 598 Removing and Installing Engine on Front Axle
11 00 598 Removing and installing engine on front axle (E72 N63)Special tools required:
Warning!
Observe safety instructions for handling hybrid cars!
Disconnect high-voltage system from power.
Necessary preliminary work:
^ Remove front axle with engine and transmission.
Release screws.
Installation note:
Replace screws.
Tightening torque 26 11 9AZ.
Slide propeller shaft towards rear and remove.
Installation note:
Slide propeller shaft fully towards rear.
Sealing cup (1) must snap audibly into place and rest entirely on dust guard (2).
Open thermal protection coating (1).
Push lock (2) up to stop.
Disconnect connector and release high-voltage cable from holder.
Installation note:
Lock (2) must snap audibly into place.
Perform pull-off test to check whether plug connection is locked.
Release screw (1) and holder from gearbox oil lines.
Tightening torque 17 22 3AZ.
Release screws (1).
Tightening torque 17 22 1AZ.
Disconnect hydraulic lines (2) to transmission oil cooler.
Seal off connections and lines with plugs!
Installation note:
Replace sealing rings.
Disconnect plug (1).
Insert special tool 24 2 390 in sealing sleeve (1).
Disconnect plug (2).
Seal sealing sleeve (2) with suitable means (e.g. adhesive tape) to prevent dirt contamination.
Release cable from holders.
Release screw (1) and remove crankshaft sensor.
Disengage cable from holder (2).
Detach connector (3) from oil pressure switch.
Unclip the transmission wiring harness from its holders (2 3 4 and 5).
Pull off the transmission wiring harness from the transmission at the holder (1).
Unlock fuse (1) at the bottom and press together the locking clamps.
Pull off plug (2).
When unflanging the gearbox, pay attention to installation position of rubber plug (1).
Note:
Graphic on ZF transmission.
Release screws.
Tightening torque 24 00 1AZ.
Screw guide pins 24 0 320 for guiding gearbox into two opposite screw points while dismantling.
In this position, the gearbox is pulled off the gearbox input shaft.
Important!
Do not release wishbone from swivel bearing with impact tool.
Make sure special tool rests correctly on steel bush of swivel bearing. The swivel bearing must be removed if the steel bushing moves.
Rubber boot of wishbone must not be damaged!
Do not pull stainless steel ring off journal.
Slacken nut (1) two to three thread turns.
If necessary, replace lower section 31 2 242 with lower section 31 2 247.
Press wishbone (2) with special tool 31 2 240) off swivel bearing.
Keep wishbone to swivel bearing connection clean and free from oil and grease.
Replace self-locking nut.
Tightening torque 31 12 4AZ.
Slacken nut (1) two to three thread turns.
If necessary, replace lower section 31 2 242 with lower section 31 2 247
Press trailing link (2) with special tool 31 2 240 off swivel bearing.
Unscrew nut (1) and remove trailing link (2) from swivel bearing.
Installation note:
Keep trailing link to swivel bearing connection clean and free from oil and grease.
Replace self-locking nut.
Tightening torque 31 12 2AZ.
Slacken nut (1) two to three thread turns.
If necessary, replace lower section 31 2 242 with lower section 31 2 246
Press track rod end (2) with special tool 31 2 240 off swivel bearing.
Unscrew nut (1) and remove track rod end (2) from swivel bearing.
Installation note:
Keep track rod end to swivel bearing connection clean and free from oil and grease.
Replace self-locking nut.
Tightening torque 32 21 3AZ.
Release screw and remove oil lines (2).
Tightening torque, 17 22 4AZ.
Installation note:
Replace sealing rings.
Recycling:
Catch and dispose of escaping oil with auxiliary materials.
Remove swivel bearing (1) with brake disc and drive shaft (3) with the aid of a workshop crane (2).
Do not bend output shaft (3) too far, note deflection angle.
The graphic shows the procedure on the left swivel bearing; the procedure on the right swivel bearing is identical.
Release screw (1).
Lay ground strap (2) to one side.
Release all nuts (2).
Release holder for high-voltage cable (1).
Fold back high-voltage cable (1).
Release all screws on transmission.
Tightening torque 24 00 1AZ.
Installation note:
Screws have different lengths.
Note installation position.
Slightly raise engine with workshop crane and special tool 11 0 020.
This simplifies removal and installation of transmission.
Recycling:
Capture emerging transmission oil with a suitable drip tray.
Release mounting bolt (1) on table lift.
Detach mounting plate (B) with transmission from engine in direction of arrow.
Unscrew nuts (1).
Raise engine.
Installation note:
Replace self-locking nuts.
Tightening torque 22 11 2AZ.
Lift engine (1) with workshop crane (2) and special tool 11 0 020 from front axle.
Mount engine on assembly stand.
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