11 00 050 Removing and installing engine (N20)
Special tools required:
Necessary preliminary tasks:
- Disconnect NEGATIVE BATTERY LEAD .
- Secure engine hood in SERVICE POSITION .
- Remove EXHAUST SYSTEM .
- Remove TRANSMISSION .
- Remove both front WHEELS .
- Remove OUTPUT SHAFTS at front (all-wheel drive vehicles only)
- Drain ENGINE OIL .
- Remove INTAKE SILENCER HOUSING .
- Remove FAN COWL with electric fan.
- Remove COOLANT THERMOSTAT .
- Detach all coolant hoses from engine.
- Draw off HEATING AND AIR CONDITIONING SYSTEM .
For removing and installing the engine, the towing hook 72 15 8 108 670 is required.
Unlock and pull off vacuum connections (1 and 2) from vacuum accumulator.
Remove acoustic cover (1) in following steps:
- Raise upward
- Remove in direction of travel
Installation note:
Insert acoustic cover (1) into existing rubber guides.
Unlock snap fastener (1).
Unlock snap fastener (1).
Remove charge air duct (2).
Installation note:
Perform a visual inspection of the form seal ring to check it for correct seating and damage.
VDA couplings are correctly fitted when they snap into place with an audible click.
Release screw (1).
Disconnect plug connection (2).
Unlock snap fastener (3).
Unfasten hose clamp (4).
Installation note:
Visually inspect the form sealing ring (1) for correct position and damage.
Coat all mounting fittings with anti-friction agent (2).
Installation note:
VDA couplings are correctly fitted when they snap into place with an audible click.
Unlock snap fastener (1).
Installation note:
The snap fastener (1) must snap audibly into place!
Installation note:
Visually inspect the form sealing ring (1) for correct position and damage.
Coat all mounting fittings with anti-friction agent (2).
Installation note:
VDA couplings are correctly fitted when they snap into place with an audible click.
Unlock and pull off all connectors (1) from the DME control unit (2).
Release screws.
Tightening torque 12 14 1AZ .
Remove DME control unit.
Unfasten engine wiring harness and lay to one side. See WIRING HARNESS FOR ENGINE SENSOR SYSTEM MODULE 1 and WIRING HARNESS SECTION FOR IGNITION/INJECTORS .
Press and hold lock (1) of tank ventilation line (2).
Pull off tank ventilation line (2).
Detach plug connection (1) at tank vent valve (2).
Detach tank vent valve (2) from bracket.
Disconnect plug connection (1) on throttle valve drive.
Unlock connector (1) and remove.
Unscrew nuts (1).
Tightening torque: 11 61 1AZ .
Remove the intake air plenum.
Installation note:
Replace all gaskets.
Release screws (1) from below.
Tightening torque 11 51 1AZ .
Loosen hose clamps (1).
Installation note:
Note the installation position of the hose clamps.
Tightening torque 11 51 3AZ .
Release coolant hoses (1 and 2).
Disconnect connector (4).
Release screw (3).
Remove coolant pump (5) toward the top.
Remove the holder for the coolant pump (all-wheel drive vehicles only).
Mark the direction of travel of the drive belt if it is to be reused.
Release screws (1).
Turn engine at central bolt until belt pulley jumps to relieved position.
The belt pulley (1) is now located in the dismantling and installation position (see arrow).
Remove drive belt (2).
Continue turning the engine at the central bolt until the belt pulley (1) jumps to the installation position (see arrow).
Attach the belt pulley with screws (1).
Tightening torque: 32 41 3AZ .
Remove circlip (1) and take off belt pulley (2) in direction of arrow.
Installation note:
Belt pulley can only be screwed-in in one position!
-> When positioning the belt pulley make sure that the belt pulley bore holes are aligned to the threaded holes on the drive flange
Release screws (3 screws) and remove vane pump (1) upward.
Installation note:
- Screw in and tighten screws uniformly
Tightening torque 32 41 6AZ .
Release screws (1) and remove refrigerant lines.
Tightening torque 64 52 1AZ .
Installation note:
Replace sealing rings.
Use special tool 00 9 030 to install sealing rings without damaging them.
Unfasten plug connection (2) and disconnect.
Open the holder (1) with suitable tools.
Clip refrigerant line (2) out of holder (1).
Installation note:
Check that the refrigerant line (2) is correctly seated in the holder (1)!
Evacuate the air conditioning.
Release screws (1) of A/C lines and disconnect.
Do not remove air conditioning compressor.
Detach the fuel line at the snap fastener (1).
Close off fuel line with special tool 13 5 161 .
Close off fuel line with special tool 13 5 162 .
Release the clamping bolt (1) on the side of the wheel arch on the left (all-wheel drive vehicle only).
Release clamping bolt (1) in engine compartment (rear-wheel drive only).
Move steering to straight-ahead driving position and remove the ignition key.
Detach lower section of steering spindle from steering gear.
Set down the steering shaft in the engine compartment on the side.
Installation note:
Clean screw threads to remove all remnants of screw locking adhesive.
Replace clamping screws.
Clamping screw must rest in groove of steering spindle lower section.
No subsequent retorquing permitted!
Steering spindle can only be attached in one position on steering gear and steering column.
Tightening torque 32 31 3AZ .
Unlock fasteners (1) from below and slide upwards approx. 10 mm.
Unlock locks (2) in direction of arrow.
Remove cover (3).
Detach all engine wiring harness section connectors from electronics box (1).
Installation note:
Make sure rubber grommets are correctly fitted (watertightness).
Risk of damage from brake lines.
Screw towing eye into cylinder head.
Tightening torque 11 12 5AZ .
Only attach special tool 11 0 000 at the mounting eyes intended for this purpose.
Lift engine out with engine crane.
Assemble engine.
Check function of DME.