Removing and Installing Engine (Vehicle With Tiptronic Transmission)
Removing and installing engine (vehicle with Tiptronic transmission)
Special tools
Removing and installing engine
The entire engine-transmission unit is removed in downward direction.
Removal
1. Put body-protection covers on vehicle.
2. Disconnect the battery and cover terminal or battery.
3. Before the vehicle is raised, the side covers of the underside panel must be removed in the rear area of the jacking points.
4. Raise vehicle at the prescribed jacking points and remove the rear wheels. Remove the centre and rear underside panels.
5. Remove rear spoiler.
6. Remove side retaining brackets (heat shield).
7. Unscrew coolant reservoir cap.
8. Undo coolant drain plug and drain the coolant; remove the coolant hoses. After draining the coolant, fit a new sealing ring on the drain plug. Tightening torque 10 + 5 Nm (7.5 + 3.5 ft. lbs.).
9. Remove air cleaner assembly:
a. Undo hexagon-head bolt M6 x 34.
b. Undo hose clamp on throttle body and pull plug off the mass air flow meter. Unclip wire on air cleaner housing and remove air cleaner assembly.
10. Disconnect oxygen sensor plug connections.
11. Detach and remove right-hand coolant hose.
12. Detach and remove left-hand coolant hose.
13. In vehicles with air conditioning, the following assembly operations must be performed:
a: Suck Pentosin fluid out of the reservoir until the level is just below the joint. Turn bayonet lock in the direction indicated by the arrow and pull off the reservoir. Immediately seal the lower reservoir with a suitable plug (30 mm �).
Bayonet lock closed
Bayonet lock open
b. Disconnect battery positive at B+ disconnection point. Undo the hexagon nuts and set the box aside.
c. Remove drive belt. Mark belt travel direction with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24 mm) clockwise , hold still and simultaneously take the belt off the drive pulleys.
d. Undo front compressor fastening screws (2 ea.). Undo rear fastening screw between the intake pipes of cylinders 4 and 5. Disconnect the electrical plug connection.
e. Lift the compressor out, set it down with the hoses connected and secure it against being dropped.
14. Disconnect plug-in couplings of the steering pressure line and the steering return line. The plug-in couplings are opened by unscrewing. (Return line
= large diameter/pressure line = small diameter.)
Collect Pentosin residues.
A open with open-ended wrench
B hold with open-ended wrench
Note;
- The steering lines also can be detached immediately after the engine-transmission unit has been lowered out of the vehicle (better accessibility).
15. Undo engine wiring harnesses (round connectors with bayonet lock) on the right side in the engine compartment.
16. Disconnect vacuum line for the brake booster. Press the black unlocking ring (arrow) and simultaneously pull the line off.
17. Disconnect plug connection of tank vent. Press unlocking buttons and simultaneously pull off the line.
18. Undo the fuel supply line and fuel return line in the engine compartment (left). It is very important to counter when performing this step. Collect residual fuel.
19. Raise the vehicle and remove the rear-axle drive shafts, diagonal braces, and front and rear cross members.
20. Undo ground strap between engine and body. Undo the strap at the engine (cylinder head, near cylinder 6).
21. Undo accelerator cable. To do this turn the left-hand rotary sleeve in the direction indicated by the arrow.
a. Unclip right-hand accelerator cable mount sleeve and disengage the accelerator cable.
22. Disengage Tiptronic plug and disconnect plug connection.
23. Disengage Tiptronic selector lever cable.
a. Disengage Tiptronic selector lever cable from the mount. Pull off coolant line.
24. Remove coolant hoses.
25. Turn round electrical connector (bayonet lock) in the direction indicated by the arrow and pull it off.
26. Prepare retainer plate (A) - special tool 9592 - for the removal operation. Place adapter (B) 9163/2 on the area of the support plate (C) 9592/1 that is identified "996" and screw the adapter together with the retaining plate 9592 (A). Screw support (D) together with the support plate.
A Retainer plate
B Adapter
C Support plate
D Support for Tiptronic transmission
27. Place pre-fitted retainer plate on the crankcase. It is recommended that the retainer plate be fitted to the crankcase first. Only then should the workshop car jack be fitted. Place car jack underneath under slight load.
28. Undo transmission support.
29. Separate engine carrier from the engine mounts (wrench size 18).
30. Lower the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time.
Note;
- Important: If the vehicle is placed on its wheels or moved in the workshop, the rear cross member should be fitted under all circumstances to maintain the structural strength.
Installation
The engine-transmission unit is installed in the reverse order. The following points must be given special attention:
1. Before the engine is installed, prepare plug-in couplings of the steering lines for plugging together:
a. Tilt holder C on one side and simultaneously pull to disengage.
b. Detach threaded part A by pulling it off the nipple.
c. Close holder C. Screw threaded part A with fitted holder C into plug-in coupling B and tighten. Counter when tightening. Tightening torque of the steering pressure line (wrench size 15) 30 Nm (22 ft. lbs.). Tightening torque of the steering return line (wrench size 19) 40 Nm (30 ft. lbs.).
2. Lift the engine-transmission unit and connect the plug-in couplings immediately prior to reaching the final installation position.
a. Insert the screwed plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.
b. Use special tool 9263 to check whether the plug-in coupling was engaged properly. Insert special tool 9263 into the groove (arrow) and apply slight pressure on the special tool to check whether the connection is securely locked (holder is seated properly). The plug must not slide out. If the special tool cannot be inserted in the groove of the plug, shift the plug in the plug-in coupling (pull on plug without using excess force).
Note;
- The plug-in connection is designed so that the plug can be shifted in the plug-in coupling by approximately 1 mm in axial direction by slightly pulling or pressing.
3. Move engine-transmission unit to installation position and fasten.
4. Place both steering lines into the holder, lift the bow and let it engage. Check whether the holder is seated properly on the body fastening point.
5. Fit engine wiring harness:
a. Line up marking of the round connector with marking on the housing.
b. Turn round connector clockwise by approximately 90° (bayonet lock).
Note;
- The round connectors are marked.
- Left connector - white mark
- Right connector - blue mark.
6. Fit air-conditioning compressor Before installation, check whether the spacer sleeve is fitted or present at the rear fastening point. Grease and fit sleeve.
7. Fit drive belt. Observe sequence when fitting the belt and direction of motion if the belt was run.
8. Fit reservoir for power steering system.
a. Remove plug.
b. Turn adjusting ring counter-clockwise to its original position.
c. Push reservoir downward and turn adjusting ring clockwise until the marks line up.
d. Fill in Pentosin. Observe the specification for bleeding.
9. Fit round connector on Tiptronic transmission.
a. Turn adjusting ring counter-clockwise to its original position.
b. Turn adjusting right clockwise until the plug engages. (bayonet lock)
10. Engage accelerator cable and close accelerator cable mount sleeve.
a. Turn rotary sleeve in the direction indicated by the arrow (closed) and line up the marks on the accelerator mount sleeve and rotary sleeve.
11. Fill in coolant and bleed cooling system.
Tightening torques: Removing and installing engine (Part 1):
Tightening torques: Removing and installing engine (Part 2):
Tightening torques: Removing and installing engine