Removing Engine

Removing engine
Tools








Tools and materials

Required tools
The following tools can be found in the Workshop Equipment Manual 3.0.13 "WE 1206" (exceptions are noted).

















Preliminary work

Special equipment-specific features are described in the notes.
^ 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 reinstalling steering-column switch'
^ Position the vehicle at the take-up points provided on a lifting platform. --> 'Lifting the vehicle'
^ Put on the protective covers.
^ Produce the OBD II log.
^ Move the Tiptronic's selector lever to position N.
^ Remove ignition key.
^ Disconnect battery.
^ Remove front wheels.
^ Remove the front wheel-housing liners.
^ Remove engine compartment covers.
^ Allow engine to cool down.



Removing the engine


WARNING: Servo oil is aggressive!
^ Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
--> Before lines are opened, place a cloth underneath them!
--> Components that come into contact with servo oil must be cleaned IMMEDIATELY with water!
--> Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)

WARNING: ATF!
^ Possible danger of injury or damage (swollen hoses, skin irritation, danger of slipping, etc.)
--> Before lines are opened, place a cloth underneath them!
--> Components that come into contact with ATF must be cleaned IMMEDIATELY with water!
--> Take suitable protective measures (e.g. gloves, safety goggles, oil binding material)
--> Collect emerging ATF!

DANGER: Fuel can escape when fuel line is disconnected.
^ Risk of fatal injury!
^ Damage to skin
--> Do not work on fuel system if engine is hot!
--> Do not smoke, avoid fire and naked flames!
--> Wear fuel-resistant protective gloves and goggles.
--> Attach warning sign to vehicle in a clearly visible position.

V6 Engine:

1. Remove engine guard with transverse strut.

Coolant Drain Plug:

2. Drain coolant.
3. Remove both wiper arms.

Bayonet Screws For Plenum Chamber Cover:

Note: The air quality sensor is located on the cover of the radiator tank. This must be unclipped.

4. Loosen the 4 bayonet screws -A- on the plenum panel cover. Then lift the cover in the middle, release left and right and remove from the vehicle.

Engine Wire Harness:

5. Disconnect the engine wire harness on the right-hand side of the vehicle. To do this, unplug the control unit and disconnect the ground point.

Torx Screws For Cover Of Central Electrical System:

6. Open the cover of the central electrical system on the left side of the vehicle. To do this, loosen the four Torx screws.
7. Disconnect the connectors from the engine wire harness (white, red, black and brown). Remove the wiring harness from the retaining clips and lay it down on the engine.

B+ Transfer Point:

8. Disconnect B+ transfer point at the left of the engine compartment. To do this, disconnect the 2 connecting cables -A and B- for the engine.

Engine Cover:

9. Pull engine cover vertically upwards and off.

Connecting Tube From Air Cleaner To Engine:

10. Remove connecting tube from air cleaner to engine. To do this, loosen the tube clamp on the engine, unplug the electric connector on the mass air-flow meter and remove the 2 fastening bolts on the air cleaner cover.

Vacuum Line:

11. Remove the vacuum line on the throttle body from the connecting tube. Then take the pressure pipe out of the engine compartment.

Note: The air tube is only present in vehicles with air suspension.

Air Tube Cap:

12. Remove air tube on air cleaner cover. To do this, unclip the green cap. Insert a screwdriver into the cut-out of the cap and lever the cap off.

Circlip:

13. Push the circlip into the adapter -1- and then pull it off together with the adapter -2-.

Cap:

14. Clip the green cap on again after disassembly.

Clamps On The Air Cleaner Housing:

15. Loosen the clamps on the air cleaner housing.
16. Remove the air cleaner cover.

Filter Elements:

Note: The slightly different illustrations between V8 and V6 show essentially the same actions.

17. Remove the filter elements.

Oxygen Sensor Connector On The Water Splash Panel:

18. Disconnect the 4 oxygen sensor connectors (brown, black) at the right of the water splash panel and unclip the cable from the supports.

Coolant Lines And Vacuum Line:

Note: The slightly different illustrations between V8 and V6 show essentially the same actions.

19. Disconnect the 2 coolant lines and vacuum line on the right side of the engine compartment.

Servo Oil Reservoir:

Note: The slightly different illustrations between V8 and V6 show essentially the same actions.

20. Empty the servo oil reservoir with a syringe. Next, remove the hose from the reservoir. Close the open connections with plugs.

Fuel Line And Carbon Canister Line:

21. Disconnect fuel line -1- and line -2- from the carbon canister on the plenum panel splash panel. Then pull off the vacuum line -3-.

Fastening Screws For Spring Struts:

22. Loosen the 3 fastening screws on the left and right spring struts. The screws are loosened from inside the engine compartment. Of the 3 screws per spring strut, one is in the plenum panel. The screws must not be re-used.

Securing Clip On Connection For Coolant Feed And Return Lines:

23. Disconnect the coolant feed and return lines from the radiator. To do this, pull out the securing clip and pull off the connection. The clips should be mounted again immediately so that they are not confused.

Note:
^ 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.

Drive Belt:

24. 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.

Note:

Compressed Air Line On Spring Strut:

^ 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.

Electric Plug Connection For Height Sensor:

^ The electric plug connection of the height sensor must be disconnected in vehicles with air suspension or automatic headlight levelling system.

Electric Plug On The Spring Struts In The Wheel Housing:

25. Disconnect electric connector -1- on the spring struts in the wheel housing. Then unclip the support -2 and 3-. Tie the cable on the spring strut.

Brake Lines In The Wheel Housing:

26. Disconnect the brake lines in the wheel well to the left and right.

Ground Point Of Right Side Member:

27. Disconnect the ground point on the right side member.

ATF Lines On Cooler:

28. Disconnect the ATF lines on the radiator. To do this, loosen the fastening screw (a/f 10) and pull the lines off. Seal open lines with a plug.

Secondary Air Pump Hose:

29. Detach secondary air pump hose. To do this, pull off the plug on the pump in the right wheel housing.

Heat Protection Shield On Steering Gear Connection:

30. Remove the heat protection shield on the steering gear connection. To do this, loosen the 2 fastening screws.

Note: For vehicles with Servotronic, an electric connector must also be removed from the steering gear.

Clamping Screw On Steering Column:

31. Loosen the clamping screw from the steering column on the steering gear and remove it. The screw must not be re-used. Force the steering column up and off the steering gear.
32. Disconnect the electric connector on the steering gear (Servotronic only).

Heat Exchanger Coolant Lines In The Left Wheel Housing:

33. Disconnect the heat exchanger coolant lines in the left wheel housing below. Approximately 2 litres of coolant will flow out when you do this.

Hydraulic Lines Under Steering Gear:

Note: In vehicles with an off road stabilizer, the two hydraulic lines under the steering gear must be disconnected. Counter with an open-ended wrench when doing this.

34. Remove the complete exhaust system from the connection point on the catalytic converter to the tailpipes.
35. Remove rear cardan shaft.

Electric Connections On The Transmission:

Loosening The Connections On The Transfer Box:

36. Disconnect electric connections -1, 2 and 3- on the transmission.

Loosening The Connections On The Transfer Box:

Note: Do not loosen screw -B-.

Selector Lever Cable On The Transmission:

37. 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.

Note: If the transmission is to be separated from the engine after removal, the 2 lower fastening screws on the transmission housing and front cardan shaft should be removed at this point, since access to the lifting platform will be impaired.

Lower Line On Servo Oil Cooler:

38. Loosen the lower line on the servo oil cooler.

Electric Connection On The Offroad Stabiliser:

39. Disconnect the electric connector on the off road stabilizer at the front left.

Note: Because of the high loosening torque, the 6 fastening screws on the suspension subframe can now be loosened. Loosen the screws by a maximum of 1 turn.

Elevating Platform Under Engine:

40. Place the elevating platform under the engine and raise it. When you do this, ensure that the positioning guides of the elevating platform are inserted into the body.

Securing The Spring Struts:

41. Secure the spring struts. To do this, turn the rubber discs upwards until they are set under the steering knuckle. Then tighten the retaining brackets on the wheel hub and elevating platform.

Fastening Screws For Transmission Cross Member:

42. Loosen the transmission cross member. To do this, loosen the 4 fastening screws -A-.
43. Secure the engine/transmission combination. Then secure the mounting mandrels on the engine transverse bar with the locking screws.

Fastening Screws For Suspension Subframe And Fastening Screws For Engine Transverse Bar:

44. Loosen the 4 fastening screws on the suspension subframe and the 2 fastening screws on the engine transverse bar.
45. Lower the lifting platform slowly by approximately 20 to 30 cm. When this is done, a second person should ensure that there is sufficient clearance around the engine compartment and wheel housings.

Note:
^ 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.

46. Loosen power steering pump. To do so, loosen the two front fastening screws and turn the pulley as required. Then loosen the rear fastening screw.

Fastening Screws And Electric Connector For The Air-Conditioning Compressor:

47. Loosen the 3 fastening screws and disconnect the electric connector from the air-conditioning compressor. Set the air-conditioning compressor aside.

Air-Conditioning Compressor:

48. The air-conditioning compressor must be secured with a piece of wire.

Note: 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.

Note: When lowering the engine, make sure that cables or lines do not get mounted accidentally between engine and body. Thus a second person should make sure that the cables and lines do not get caught.

49. 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.

Engine Removed: