Engine: Service and Repair

Removing and Installing Engine

Special Tools Required:
- 11 0 001
- 11 0 002
- 11 0 003
- 11 0 009
- 11 8 260
- 11 8 351
- 11 8 401
- 11 8 402
- 13 5 280
- 23 4 010
- 11 8 401
- 13 5 280
- 23 4 010
- 11 8 351
- 11 8 260
- 11 0 001
- 11 0 002
- 11 0 003
- 11 0 009

Turn off ignition.

Fit intercooler protector. Please refer to: Fitting Guard For Intercooler

Remove intake air filter housing. Please refer to: Removing and Installing Intake Filter Housing

Remove auxiliary drive belt, please refer to: Service and Repair

Drain gearbox, please refer to: Manual Transmission: Service and Repair





Remove lower stabilizer bracket bolts (1) and remove bracket (2)
Lower stabilizer to oil sump holder 100 Nm





Disconnect steering pump motor connectors (1).





Remove crush tubes. Front Bumper Bracket

Slacken modular front end and fit special tools 11 8 401 and 11 8 402





Remove subframe. Please refer to: Service and Repair

Remove driveshafts. Please refer to: Service and Repair

Remove exhaust manifold. Exhaust Manifold

Remove starter motor heat shield retaining bolt (1).

Remove heat shield (2).
Oil Pump cover to timing case cover inner
M8 18 Nm





Remove starter motor connections (1) and (2).
Alternator connection on starter 14 Nm
Engine harness to starter solenoid 8 Nm


Remove oil pressure connector.

Note: Harness routing.

Remove harness brackets from starter motor and cooling pipe.

Move harness to one side.





Remove reverse lamp connector from gearbox.

Remove intercooler. Please refer to: Service and Repair

Remove throttle valve. Please refer to: Service and Repair

Remove tank venting valve lower pipe from stabilizer bracket. 17 00 039 Venting Cooling System and Checking For Leaks

Remove earth lead from right engine mounting bracket.

Release fuel pressure from fuel line.

Disconnect fuel line from fuel rail via quick fit connector and fit special tool 13 5 280





Remove fusebox cover.

Disconnect connector (1) from fusebox





Disconnect earth lead (1) from left strut.
Earth connection to left hand strut 9 Nm
Disconnect connector (2).





Drain coolant. Coolant System Drain and Refill

Disconnect both heater pipe connections (1) from heater matrix.

Disconnect both expansion tank pipes (2) at heater pipe junction.

Remove top hose from radiator.

Remove top stabilizer bracket.





Remove slave cylinder retaining bolts (1) and remove slave cylinder (2).





Release gearshift cables (1) from ball joints with special tool 23 4 010.

Release and remove gearshift cables from abutment bracket (2)





Disconnect connector from A/C compressor (1).

Remove A/C compressor retaining bolts (2) and lower compressor (3). Secure compressor to modular front end.
Compressor to engine 25 Nm





Remove coolant pipe bolt (1) and disconnect map sensor connector (2).

Disconnect coolant pipe (3).
Oxygen sensor bracket to cylinder head
M8 10 Nm
Coolant line to cylinder head
M8 25 Nm





Fit engine brackets, special tool 11 8 351 and special tool 11 8 260
Engine carrier to cylinder block 100 Nm





Remove supercharger inlet retaining bolt (1) and release hose clip (2)

Remove supercharger inlet pipe (3) to access pipes (4).

Note: Disconnect pipes via quick fit connector.

Remove brake booster pipe from engine.

Release slave cylinder pipe from gearbox and move to one side.





Fit engine lifting tools 11 0 001, 11 0 002, 11 0 003 and 11 0 009.

Attach engine lifting bracket and chains to engine and support power unit with hoist.

Note: It is recommended to use the longer link chain on the right engine bracket.





Remove engine mount retaining nut (1).
Engine mounting to engine mount 68 Nm





Remove gearbox to upper mount retaining bolt (1).
Gearbox mount retaining bolt to upper bracket 66 Nm

Lower engine and remove.