Removing and Installing Engine - GT3
Removing and installing engine - GT3
Special tools
Removing and installing engine - GT3
The entire engine-transmission unit is removed in downward direction.
Removal
1. Disconnect the battery and cover terminal or battery.
2. Raise the vehicle at the prescribed jacking points. In order to avoid damage to the side member, raise the vehicle by means of a workshop jack on the engine and move the mounting plate of the lifting platform into the highest position.
3. Remove the centre and rear underside panels.
4. Remove rear spoiler.
5. Remove side retaining brackets (heat shield).
6. Unscrew cap from coolant expansion tank.
7. Undo coolant drain plug on right and left and drain the coolant. After draining the coolant, fit new sealing rings on the drain plug. Tightening torque 10 + 5 Nm (7.5 + 3.5 ft. lbs.).
8. Remove the air cleaner assembly. Undo hexagon-head bolt M6 x 34. Undo hose clamps on throttle body and pull plug off the mass air flow meter.
9. Disconnect oxygen sensor plug connections on the rear closing panel.
10. Remove right and left-hand coolant hose, lever off safety bracket to do this. Remove coolant hose on the expansion tank.
Illustration shows left-hand coolant hose
11. Undo three hexagon-head bolts on the hydraulic pump by approximately one half turn.
12. Relieve drive belt. 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.
13. Remove pulley of the hydraulic pump.
14. Unclip electric cable from the air flow sensor on the expansion tank of the hydraulic pump.
15. Undo fastening screws on the expansion tank (2 M8 screws) and the hydraulic pump (3 M8 screws and one M6). Take the expansion tank with hydraulic pump and connected lines up out of the fastening bracket and set down on the right-hand side.
16. Disconnect battery positive at B+ disconnection point.
17. The assembly work below must be performed on a vehicle with air conditioning:
a. Remove three-phase generator.
b. Undo the compressor from the bracket (3 screws).
Note;
- The throttle body can be swung upward for better accessibility to the front screw. To do this, both inner hose clamps must be removed.
c. Disconnect electrical plug connection. Lift out compressor and set it down with the hoses connected.
18. Undo engine wiring harnesses (round connectors with bayonet lock) on the right side in the engine compartment.
19. Disconnect plug connection of tank vent. Press unlocking buttons and simultaneously pull off the line.
20. Disconnect the vacuum line for the brake booster. To do this, remove the snap ring. Push the inner sleeve against the outer sleeve and pull off both sleeves together towards the rear.
21. 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.
22. Raise the vehicle and remove the stabilizer, rear-axle drive shafts, diagonal braces, and front and rear cross members.
Note;
- Drill an access bore of approximately 30 mm � on the side members for better access to the outer fastening screws on the diagonal braces.
23. 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.
24. Undo ground strap between engine and body. Undo the strap on the body (cylinder head, near cylinder 6).
25. Remove starter.
26. Move shift lever to neutral position and disengage shift cables on the transmission. Use a commercially available removal tool for this purpose.
27. Remove coolant hoses.
28. Undo clutch slave cylinder and hang to one side with the connected line.
Note;
- The clutch pedal must not be pressed if the slave cylinder has been removed. Affix a warning note in the vehicle.
29. Place workshop jack and preassembled engine retainer plate underneath with slight load. Observe the position of the engine retainer plate. Engage support lever in horizontal position. Spacer, special tool 9111/5 fitted.
30. Undo transmission support.
31. Separate engine carrier from the engine mounts (wrench size 18).
32. Lower the engine-transmission unit carefully and in steps. Have a second person observe the engine-transmission clearance at the same time, especially near the oil container.
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. Fit engine wiring harness: The round plugs are color-coded on the inside: upper plug - black lower plug - grey
a. Line up marking of the round connector with marking on the housing.
b. Turn round connector clockwise by approximately 90° (bayonet lock).
2. Fit air-conditioning compressor Liberally grease and fit the thread of the rear fastening screw and spacer sleeve.
3. Install three-phase generator.
4. Install hydraulic pump.
5. Fit drive belt. Observe sequence when fitting the belt and direction of motion if the belt was run.
6. Fit coolant hoses with new O-rings. Attach the safety brackets onto the coolant supports before engaging the coolant hoses.
7. Move coolant hoses into installation position (arrow). The coolant hoses must audibly engage when pushed into the supports.
8. 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.
9. Fill in coolant and bleed cooling system.
Tightening Torques: Removing And Installing Engine - GT3 (Part 1):
Tightening Torques: Removing And Installing Engine - GT3 (Part 2):
Tightening torques: Removing and installing engine - GT3