Part 2
WM 100119 Removing and installing engine
Installing engine
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 appropriate protective measures (e.g. use gloves, safety goggles, oil binding material)
-> Collect emerging ATF!
NOTICE
Opened refrigerant system for repairs.
- Moisture penetrated into the refrigerant system.
- Soiling of refrigerant circuit.
- Risk of saturation and irreparable damage to desiccator.
- If the desiccator has disintegrated, the desiccator, compressor and evaporator may be damaged.
-> If the air humidity is too high and if the refrigerant circuit is open for some time, it will be necessary to replace the desiccator.
Information
- Set the steering wheel with the wheels in straight-ahead position. To do this, engage the steering column lock or clamp the steering wheel in centre position with a steering-wheel holder. If this is not done, the airbag contact unit will have to be moved to centre position after installation of the steering gear. -> 945019 Removing and installing steering-column switch Service and Repair
Information
- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
Information
- Due to currently correct tightening specifications, the screw specifications can be found in the corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc.
1. Guide the engine in under the vehicle.
Information
Check the position of all lines, hoses and cables again during and following installation. Make sure that:
- The lines, hoses and cables are not installed twisted (markings on steel flexi-pipes!)
- The lines, hoses and cables are not exposed to any mechanical strain from the outside while driving, i.e. they must not be over-strained or deformed.
- The lines, hoses and cables are not rubbing against other moving components.
- The lines, hoses and cables cannot become clamped.
1.1. Move engine under the vehicle using the lifting platform.
1.2. Position the wheels of the lifting platform at the position marked during removal.
1.3. Guide the engine up into the engine compartment using the lifting equipment.
1.4. Gradually guide the air-conditioning lines => Air-conditioning lines along with your hand.
Air-conditioning lines
1.5. Fit the locking cable at half height (easier to access).
-> 371319 Removing and installing locking cable
1.5.1. Pull the locking cable down and engage it in the support.
1.5.2. Fit parking lock cable at the ball joint on the transmission.
2. Fit the front-axle carrier.
For tightening torques and other details, see: -> 400619 Removing and installing front-axle carrier 400619 Removing and installing front-axle carrier
Marking and fastening screws on front-axle carrier
2.1. By adjusting the position of the lifting platform slightly, move to the marking -arrow- for the contact points for the front-axle carrier on the longitudinal members.
2.2. Fit fastening screws securing front-axle carrier to the longitudinal members on both sides.
3. Fit fastening screws -arrows- on the rear transmission mount.
For tightening torques and other details, see: -> 343519 Removing and installing transmission
Fastening screws on transmission mount
4. Fit fastening screws -arrows- securing the anti-roll bar mount to the supporting plate on both sides.
For tightening torques and other details, see: -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
Fastening screws on supporting plate
5. Fit transverse struts -2-.
For tightening torques and other details, see: -> 4X00IN Tightening torques for front axle 4X00IN Tightening torques for front axle
Removing struts (right side shown here)
5.1. Right side: Press rear wheel housing cover -1- down -arrow- and fit the transverse strut -2- between the supporting plate and door sill.
5.2. Left side: Fit transverse strut between the supporting plate and door sill.
6. Guide in and fit bolt on the lower control arm -arrow-.
For tightening torques and other details, see: -> 4X00IN00 Tightening torques for front axle
Bolts on lower control arms
7. Remove wheel hub holder -1- on the lifting platform and remove assembly pins -2- on the wheel hub.
Wheel hub holder (shown here on steel brake disc)
8. Lower and push away.
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 appropriate protective measures (e.g. use gloves, safety goggles, oil binding material)
-> Collect emerging ATF!
9. Fit supply and return hose for the ATF transmission fluid cooler -arrow-.
For tightening torques and other details, see: -> 386019 Removing and installing ATF cooler Service and Repair
Supply and return hose for transmission fluid cooler
Information
- Set the steering wheel with the wheels in straight-ahead position. To do this, engage the steering column lock or clamp the steering wheel in centre position with a steering-wheel holder. If this is not done, the airbag contact unit will have to be moved to centre position after installation of the steering gear. -> 945019 Removing and installing steering-column switch Service and Repair
10. Fit universal joint -1-.
For tightening torques and other details, see: -> 481519 Removing and installing steering column 481519 Removing and installing steering column
Fitting universal joint
10.1. Pull universal joint -1- and lower part of steering column -arrow- downwards.
10.2. Fit clamping screw -2-.
10.3. Vehicles with Servotronic: Plug in connector -3-.
10.4. Fit holder at cable of Servotronic connector.
11. Fit heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.
Heat protection panel
11.1. Guide in heat protection panel -1-.
11.2. Fit the fastening screws -2-.
12. Fit PDK wire harness.
12.1. Plug in connectors on the end of the PDK wire harness -2- at the transmission, lock them -1- and fit the retaining clip -3-.
Connectors on PDK wire harness
12.2. Fit retaining clips -arrows- for the PDK wire harness.
Retaining clips on PDK wire harness
12.3. Guide in heat protection panel for PDK wire harness and fit fastening screws -arrows- on the transmission.
Heat protection panel for PDK wire harness
NOTICE
Opened refrigerant system for repairs.
- Moisture penetrated into the refrigerant system.
- Soiling of refrigerant circuit.
- Risk of saturation and irreparable damage to desiccator.
- If the desiccator has disintegrated, the desiccator, compressor and evaporator may be damaged.
-> If the air humidity is too high and if the refrigerant circuit is open for some time, it will be necessary to replace the desiccator.
13. Fit air-conditioning compressor accessories.
Flexible-head socket wrench, a/f 10 9824/1
Torx Micro Bit T45 9824/3
For tightening torques and other details, see: -> 873419 Removing and installing air-conditioning compressor
13.1. Fit intake pipe and pressure line -1 and 2- on the air-conditioning compressor.
Air-conditioning compressor lines
13.2. Guide air-conditioning line holder into the guide -2-.
Air-conditioning line holder
13.3. Fit fastening screw -1- on air-conditioning line holder.
14. Fit reinforcement plate -1-.
For tightening torques and other details, see: -> 400619 Removing and installing front-axle carrier 400619 Removing and installing front-axle carrier
Reinforcement plate
14.1. Position reinforcement plate -1-.
14.2. Screw in fastening screws -2-.
15. Left side: Fit return hose for hydraulic oil cooler.
15.1. Fit return hose -2- at the hydraulic oil cooler.
Return hose for hydraulic oil cooler
15.2. Screw in fastening screw -1- between the hose clamps.
Information
Working with steel flexi-pipes
- Steel flexi-pipes are particularly prone to kinking and pinching.
- Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
- Mark the installation position of the pipe with a paint marker during removal.
- Steel flexi-pipes must never be installed twisted.
16. Left side: Fit steel flexi-pipe to the expansion hose. => Steel flexi-pipe to expansion hose
16.1. Fit steel flexi-pipe to the expansion hose in line with the marking applied during removal.
Steel flexi-pipe to expansion hose
17. Fit ambient air valves.
Ambient air valve
17.1. Fit ambient air valve at the suction hose -1- on both sides.
17.2. Fit ambient air valve at the pressure hose -2- on both sides.
17.3. Fit vacuum line -3- for the charge-air cooler at both sides.
18. Fit suction hose -arrow- on both sides by tightening the hose clamps -arrow-.
Suction hose
19. Fit pressure hose on the charge-air cooler at both sides. => Pressure hose on charge-air cooler
Pressure hose on charge-air cooler
20. Lower the vehicle halfway.
21. Right wheel housing: Fit fastening nut -arrow- on the ground cable for the engine at the frame carrier.
=> Tightening torque: 10 Nm (7.5 ftlb.)
Ground cable
Information
Working with steel flexi-pipes
- Steel flexi-pipes are particularly prone to kinking and pinching.
- Be particularly careful with steel flexi-pipes during removal, storage and reinstallation.
- Mark the installation position of the pipe with a paint marker during removal.
- Steel flexi-pipes must never be installed twisted.
22. Fit steel flexi-pipes on the PDCC valve block at the front.
22.1. The installation position of the steel flexi-pipes -2- was marked on the steel flexi-pipes and on the valve block during removal -3-.
22.2. Fit cap screws on steel flexi-pipes -1- and screw them in until the markings are aligned.
Steel flexi-pipes
23. Left wheel housing: Fit fastening nut on holder for power-steering pressure line. => Fastening nut on holder
Fastening nut on holder
24. Fit chassis components.
24.1. Fit fastening nuts -1- on the upper control arms at both sides.
Fastening nuts on upper control arms
24.2. Fit fastening nut on connecting link -arrow- at the spring strut on both sides.
Fastening nut on connecting link
24.3. Fit fastening nut -1- on the lower control arm at both sides.
Fastening nuts on lower control arms
25. Connect plug connection for rpm sensor on both sides. => Connector for rpm sensor
Connector for rpm sensor
26. Disconnect the secured coolant hoses and pressure hoses on the charge-air cooler from the lock carrier. => Hoses secured to the lock carrier
Hoses secured to the lock carrier
26.1. Fit coolant hoses on the engine block at both sides. => Coolant hoses
Coolant hoses
27. Connect wastegate control lines -arrow- on both sides at the T-piece.
Wastegate control line
28. Fit air box on throttle valve.
28.1. Fit hose clamps on the air box -arrows- at both sides.
Hose clamps
28.2. Fit bayonet bolt -arrows- at the air box.
Bayonet bolt
28.3. Plug in connector for boost pressure sensor -arrow-.
Connector for boost pressure sensor
28.4. Install design cover.
-> 108319 Removing and installing engine cover (design cover) Service and Repair
29. Fit hose for hydraulic oil tank. => Hose for hydraulic oil tank
Hose for hydraulic oil tank
30. Fit hose for coolant reservoir -arrow-.
Hose for coolant reservoir
31. Fit positive cable at the jump-lead starting point.
31.1. Release flap on jump-lead starting point. => Jump-lead starting point
Jump-lead starting point
31.2. Fit positive cable for the battery at the jump-lead starting point.
31.3. Lock the flap for the jump-lead starting point.
32. Fit breather hose on the bleeder valve => Breather hose.
Breather hose
33. Guide coolant hoses into the connection point and lock with the clip. => Fitting coolant hoses
Fitting coolant hoses
34. Fit secondary-air pump and hose. => Fitting secondary air pump -> 266519 Removing and installing secondary-air pump with bracket Service and Repair
Fitting secondary air pump
35. Connect plug connections for oxygen sensors -1- at both sides.
Oxygen sensor plug connection
36. Install upper torque support.
-> 103719 Removing and installing torque support 103719 Removing and installing torque support
NOTICE
Aggressive fluids
- Risk of damage to components and surfaces
-> Do not spill fluids.
-> In the event of contact, wash the component or surface with water.
-> Replace components that are already damaged.
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 vapours.
-> Attach warning sign in a clearly visible position.
37. Fit fuel low-pressure line.
37.1. Fit tank ventilation and vacuum line => Tank ventilation and vacuum line.
Tank ventilation and vacuum line
37.2. Fit the fuel low-pressure line by countering with a wrench. Counter at the centre piece and fit the union nut at the engine side. => Tightening torque: 30 Nm (22 ftlb.) => Fuel low-pressure line
Fuel low-pressure line
38. Install wire harness in the plenum panel.
38.1. Fit sleeve with wire harness into the on-board panel. => Sleeve with wire harness
Sleeve with wire harness
38.2. Release and lift up the relay fuse box in the plenum panel on both sides -arrows-. Route wire harness for DME control unit underneath in the plenum panel.
Lifting up relay fuse box
38.3. Engage the locking lugs for the relay fuse box in the plenum panel.
38.4. Plug in connectors on the DME control unit.
Subsequent work
Information
- Following replacement of the high-pressure pump and engine, the values for the high-pressure adaptation must be reset using the PIWIS Tester. Then carry out a test and adaptation drive. Read the information in the section -> 24701900 Removing and installing DME (DFI) control unit.
- The current software must be installed on the control unit if necessary. Following conversion to a new engine, it is possible that an old software version may still be installed on the control unit.
1. Install front left wheel housing liner completely on vehicles with PDCC.
-> 505619 Removing and installing front wheel housing liner Removal and Replacement
2. Install front part of front wheel housing liner at both sides.
-> 505619 Removing and installing front wheel housing liner Removal and Replacement
3. Install brake caliper on both sides.
-> 473919 Removing and installing front brake caliper 473919 Removing and installing front brake calliper
-> 473919 Removing and installing front brake caliper (PCCB) 473919 Removing and installing front brake calliper (PCCB)
4. Install cardan shaft.
-> 393519 Removing and installing rear cardan shaft Service and Repair
5. Install underbody panelling.
-> 519219 Removing and installing cover for front underbody 519219 Removing and installing Cover For Front Underbody
-> 519319 Removing and installing cover for centre underbody 519319 Removing and Installing Cover for Centre Underbody
-> 519419 Removing and installing cover for rear underbody 519419 Removing and Installing Cover for Rear Underbody
6. Install rear profile seal. -> 553319 Removing and installing front lid seal 553319 Removing And Installing Front Lid Seal
7. Install transverse control arm cover.
-> 852219 Removing and installing plenum panel cover 852219 Removing and installing plenum panel cover
8. Install cowl panel cover.
-> 508719 Removing and installing cowl panel cover Service and Repair
9. Connect battery ground strap.
-> 9X00IN Work instructions after disconnecting the battery 9X00IN Work instructions after disconnecting the battery
10. Fill in coolant.
-> 193817 Draining and filling coolant Service and Repair
11. Fill in refrigerant for the air conditioning system.
-> 870317 Draining and filling refrigerant Service and Repair
12. Fill the hydraulic oil tank.
-> 430955 Replacing reservoir (PDCC) 430955 Replacing reservoir (PDCC)
-> 489755 Replacing reservoir Service and Repair
13. Bleed power steering.
-> 480201 Checking hydraulic fluid (fluid level) 480201 Checking hydraulic fluid (fluid level)
14. Check ATF level.
-> 370235 Checking and topping up ATF 370235 Checking and Topping Up ATF
15. Check engine-oil level.
-> 170101 Checking engine-oil level 170101 Checking engine oil level
16. Perform suspension alignment.
-> 449503 Suspension alignment, complete 449503 Suspension Alignment, Complete
17. Adjust the locking cable.
-> 370015 Adjusting locking cable
18. Test-drive the vehicle.
Check the fluid level in the reservoir after the coolant circuit has cooled again and fill up to the max marking with coolant if necessary.