Part 1
WM 100119 Removing and installing engine
Preliminary work for removing engine
Preliminary work
Information
Take care to maintain access to the screws for the diagonal struts in the vicinity of the rear jacking points.
Danger
Vehicle can fall down
Risk of squashing or crushing
Risk of damage to the vehicle
- Do not place any solid objects under the raised vehicle.
- Ensure that the lifting platform is prevented from lowering.
- Remove solid objects before lowering the vehicle.
- Raise the vehicle only at the take-up points provided.
1. Raise the vehicle at the prescribed jacking points.
2. Use the PIWIS Tester to readout the fault memory.
3. Place protective covers on the body to avoid damage.
4. Disconnect the battery and cover the battery or contacts.
5. Remove both rear wheels. Use the specified special tool socket-wrench insert 300 to avoid damage to the wheel rims.
6. Remove rear apron.
7. Removing side retaining frames (heat protection) at the left and right.
8. Undo support securing rear apron to body -2-. Turn the support towards the brake disc.
Rear apron support
9. Remove cover for rear and center underbody.
Removing engine
Removing engine
Caution
Hot components
Risk of burns
- Let hot components cool down.
- Wear personal protective gear.
Information
The spring band clamp is vulcanized on the coolant supply hose of the coolant expansion tank to the engine! The vulcanization diminishes after the clamp has been opened and tightened several times. Therefore do not pull off as this could damage the hose.
Information
Following removal, place the air conditioning compressor on a suitable protective support (e.g. foam, neoprene).
Information
If the holder on the servo line's plug-in coupling needs to be replaced, the special tool assembly aid 9622 is already contained in the parts set.
Information
If the vehicle is placed on its wheels or moved in the workshop, the rear cross member must always be refitted.
If the cross member is not refitted, the vehicle will have to be aligned after the engine is installed.
1. Remove the air cleaner housing completely.
2. Open cap on coolant expansion tank -1-, fold up bleeder valve -2-.
Cap on coolant expansion tank
Warning
Caustic fluid
Danger of chemical burns
- Avoid contact with caustic fluid.
- Wear personal protective gear.
- Ensure that there is good ventilation.
- If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.
3. Drain coolant.
3.1. Open coolant drain plug and refit with new sealing ring - Tightening torque: 10 Nm (7.5 ftlb.)
3.2. Open coolant supply line (Henn coupling) to engine at underbody and reconnect it.
3.3. Heating supply and return lines (open spring band clamps in direction of radiator)
Coolant supply line (Henn coupling) to engine
4. Open line connections in engine compartment.
4.1. Loosen the vacuum lines for the brake booster -1-. For the tandem pump supply line, remove the plastic protection, push the holder forward and pull off the line. Immediately put plastic protection back in place.
4.2. Disconnect tank vent line -2-. To do this, press the lugs of the rapid-action coupling and pull off the line.
4.3. Disconnect bleeder hose from coolant expansion tank -3-.
Left engine compartment line connections
5. Disconnect coolant pump feeder hose -1-. Open spring band clamp -2- and pull off the hose.
Coolant pump coolant feeder hose
6. Pull off hose from coolant pipe under coolant expansion tank -1-. To do this, lift the safety clip on the Henn coupling out of the lock -arrow- using a screwdriver and pull out the hose. Plug the opening with a clean cloth. Put the safety clip back in place after removing the engine
Coolant pipe feeder hose
7. Pull off tandem pump feeder line -1- and right coolant pipe feeder hose -3-. Open and remove spring band clamp on vacuum line. Then, lift safety clip on Henn coupling out of the lock -2- and pull off coolant hose. Plug the opening with a clean cloth. Put the safety clip back in place after removing the engine.
Right coolant pipe hose
8. In Tiptronic vehicles, pull the coolant hose to the disc valve off the transmission. Clamp the hose -arrow-, open the spring band clamp and pull off the hose. Collect escaping coolant, close off hose and disc valve with stoppers.
Coolant hose to disc valve
9. Before opening the fuel lines, place a warning sign in a clearly visible position at the vehicle.
Warning sign
Warning
Highly inflammable or explosive materials
Danger of fire or explosion
- Avoid contact with hot parts or sources of ignition.
- Use suction to remove ignitable vapors.
- Attach warning sign in a clearly visible position.
10. Open fuel supply line. Press the locking lugs on the rapid-action coupling and pull off the line. Soak up emerging fuel with a cloth.
Rapid-action coupling on fuel line
11. Unclip fuel line from holder on coolant expansion tank -arrow-.
Holder for fuel line
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
12. Unclip oxygen sensor plug connections -1,2- on the left and right in the engine compartment from the holder. Press the red locking lugs upwards using a small screwdriver and pull out the connectors. The connectors are color coded to avoid confusion.
Oxygen sensor connectors in engine compartment
13. Loosen drive belt. Mark the running direction of the belt with a colored pen. Slacken belt by turning the tensioning pulley (wrench size 24) clockwise -arrow-, hold tightly and simultaneously take the drive belt off the deflection pulley. Carefully allow the tensioning roller to turn back into tensioning position.
Drive belt tensioning pulley
Information
The air-conditioning lines on the compressor do not need to be disconnected in order to remove the engine/transmission unit.
Following removal, place the air conditioning compressor on a suitable protective support (e.g. foam, neoprene).
14. Remove air conditioning compressor.
15. Disconnect ground connector from intake distributor side 4-6 -arrow-.
Air conditioning compressor ground line
16. Pull the engine compartment temperature sensor out of the intake distributor 4-6 together with the rubber sleeve -1- and unscrew the rear fastening screws -2- on the air conditioning compressor.
Rear fastening on air conditioning compressor
17. Unscrew the front fastening screw -arrow- on the air conditioning compressor. Due to the restricted accessibility, the use of a 3/8" extension, 16 degrees movable NR.15 with a long Torx E10 socket wrench is recommended. To lift out the air conditioning compressor, the screw must be pulled upwards and held in position.
Front fastening screw on air conditioning compressor
18. Remove the holder for the servo lines, lift out the air conditioning compressor with the connected lines and place on its side on a protective support. Also secure it with a tie-wrap.
19. Disconnect engine wire harness (two round connectors with bayonet locks) from the plug connections in the right of the engine compartment. To do this, open the bayonet locks by turning them anti-clockwise.
Engine wire harness round connectors
20. Open tie-wrap -arrow- on engine wire harness cable guide and lay wire harness on engine.
Engine wire harness fastening
Warning
Danger of injury and material damage when using Pentosin.
Risk of skin irritation and damage to skin.
Damage to hoses and wiring.
- Wear protective gloves and goggles.
- In the event of contact (eyes or skin), wash immediately with water.
- Collect emerging Pentosin.
- Use caps to protect the wiring against soiling and damage.
- Clean hoses and wiring immediately.
21. Open power steering pressure pipe and return line. Loosen screws on pressure line (counter) -1-. Open spring band clamp on return line (hose).
Servo lines in engine compartment
22. Pull off return hose and open pressure pipe. Collect escaping Pentosin in a small container and then close off the return line again.
Collecting Pentosin
23. Loosen pressure pipe nipple -A- on the pipe. Tilt holder on one side -C, arrow- and simultaneously pull to disengage. Detach nipple from the pipe and remove the old O-ring. Close off line.
Removing pressure pipe holder
24. Place holder -C- into threaded part -A- and, if necessary, fasten using assembly aid 9622 . Screw threaded part with new O-ring into the screw coupling -B- and tighten. Always counter when tightening. - Tightening torque: 30 Nm (22 ftlb.)
Servo line plug-in coupling
25. Tie up oil filler neck with welding wire, string or tie-wrap.
Tying up oil filler neck
26. Release drive shafts from transmission (a second person should actuate the brake pedal to hold it). Slide a suitable protection (e.g. an open plastic pipe, an old coolant hose with a diameter of about 30 mm) over the shaft in the area of the rear axle or place foam padding underneath it.
Manual transmission drive shaft
27. In Tiptronic vehicles, an aluminium spacer ring is installed between the drive shaft and the transmission flange. These rings must be removed.
Spacer ring on Tiptronic drive shaft
28. Disconnect the ground strap on the underside between the engine and the body. Unscrew one M8 hexagon nut -arrow-, remove ground strap from threaded pin.
Engine ground strap
29. Remove rear anti-roll bar. Unscrew two M8x40 hexagon-head bolts -1- on the left and right. Remove the M10 hexagon nuts on the connecting rod while holding the internal Torx -2- to counter. Remove anti-roll bar.
Rear anti-roll bar mount
30. Remove the front transverse strut, both diagonal braces and the rear cross member.
30.1. Front transverse strut -A-: unscrew two M10x40 hexagon-head bolts.
30.2. Diagonal braces -B-: Unscrew two hexagon-head bolts (M12 x 30) on the rear cross member, two hexagon head bolts (M10x40) at the front and two M10 hexagon nuts on the rubber mounts.
30.3. Rear cross member, lower fastening -C-: Unscrew two M12 hexagon nuts while holding the M12x80 hexagon head bolts to counter, pull both screws out of bore holes.
Cross member with accessories
31. Rear cross member, top fastening: Loosen (do not remove) two M12 hexagon nuts (long slots on cross member), take off cross member downwards.
Top fastening of rear cross member
32. Open B-Plus box on transmission -arrow-, unscrew hexagon nut and disconnect the cables.
B-Plus box on Tiptronic transmission
33. Manual transmission: Unclip B-Plus line from shift console -1- and pull through in direction of travel.
Manual transmission B-Plus line
34. Tiptronic transmission: Detach selector cable. Lever out selector cable end piece -1- at the ball head of the selector lever -arrow- using a screwdriver.
Tiptronic selector cable joint
35. Unclip Tiptronic transmission cable plug and then disconnect plug connection.
Tiptronic cable plug
36. Manual transmission: Detach shift cables from the support bracket. Lever off the end pieces from the ball heads of the external shift mechanism. Press the safety clips together and pull the cable sleeves out of the support bracket.
Shift cable joint for manual transmission
37. Manual transmission: Disconnect cable plug for reverse gear switch and unclip from cable guide.
Cable plug for reverse gear switch of manual transmission
38. Remove the hall sender from cylinder bank 4-6. Unscrew one M6 hexagon socket head bolt (micro-encapsulated) -1- pull hall sender -2- out of the drilling and hang to one side.
Hall sender cylinder bank 4-6
39. Attach special tool retainer plate 9592 to engine.
40. Screw special tool support plate 9592/1 to retainer plate in position -9592- using four M8x20 hexagon bolts.
40.1. Screw special tool mounting peg 9163/2 to the support plate in the marked position -996- using four M8x25 hexagon bolts.
Support plate 959211 with adapter 9163/2 on retainer plate
41. Tiptronic vehicles: Attach special tool support plate 9592/2 to the support plate 9592/1 using three fastening screws.
42. Manual transmission: to support the manual transmission, attach scantling (approx. 6.5 cm) -2- to support plate 9592/1 -1- using a wooden bolt.
Support for manual transmission
43. Attachment of scantling -arrow- to support plate 9592/1
Scantling bolting
44. Engine retainer plate fully attached to engine.
Engine retainer plate fully attached to engine (Tiptronic).
1-support plate on retainer plate: position 9592
2-mounting plate 9163/2 on retainer plate: position 996
3-support plate 9592/2 for Tiptronic transmission
4-fastening for support plate 9592/2
45. Fasten mounting plate for sports cars -2- to the Master Gear unit lifting platform (see figure) using four screws and nuts. To counter the tilt of the engine within the vehicle, the plate must be raised by 6 mm on one side in the opposite direction to the direction of travel. This can be achieved for example by using two sheet steel panels -1- or thick washers for the rear screws.
Mounting plate on Master Gear
Alldata editors note:
A. 997 Carrera/Cabriolet/Targa 4/4S AWD Vehicles Only: Remove cardan shaft.
B. Pull cardan shaft out of the front-axle final drive and set it aside.
Cardan shaft threaded joint
46. Remove the transmission support. Unscrew four M10 hexagon nuts and two M10x55 hexagon-head bolts and remove the transmission support.
Transmission support
47. Undo the screw connection of the transmission bracket. Loosen two M10 hexagon-collar nuts on the transmission bracket (do not unscrew completely!)
48. Position unit lifting platform under the vehicle and position the take-up bore of the mounting peg -1- with a slight degree of pre-tension.
Unit lifting platform engine mounting
49. Unscrew two M10 hexagon-collar nuts from the transmission bracket.
50. Loosen two M12 hexagon-collar nuts on the engine carrier (wrench size 18) and unscrew.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
51. Slowly lower the engine/transmission unit about half-way with the lifting platform.
52. Remove cable holder and sheet metal bracket for the plug connection of the pulse sender. Unscrew one M6x12 hexagon-head bolt, unclip cable from the cable holder and unscrew it. Put plug connection with cable to one side.
Pulse sender holder and connector
53. Manual transmission: remove clutch slave cylinder. Unclip line -2-, unscrew two fastening screws -3- and remove cylinder.
Clutch slave cylinder
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
Notice
Engine/transmission unit lowered or inserted incorrectly
Risk of damage to engine/transmission unit
Cables and coolant hoses can be stretched and torn
- Gradually lower or raise the engine using a jack.
- Always check that all necessary cables were disconnected when lowering the engine/transmission unit.
- Make sure that no cables or hoses are damaged when fitting the engine/transmission unit.
- Get one or two more persons to help.
54. Lower the engine/transmission unit completely with the lifting platform.