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Removing and Installing engine


I thought you guys might like this. This is from Porsche on how to remove and reinstall the engine.

WM 100119 Removing and installing engine

Tools

Designation Type Number Description

Master Gear unit elevating platform Workshop equipment WE 1206

Flexible-head socket wrench, a/f 10 Special tool 9824/1

Torx Micro Bit T45 Special tool 9824/3

Spring compressor VW tool VW 552

Technical values

Location Description Type Basic value Tolerance 1 Tolerance 2

Ground cable for engine to body M8 Tightening torque 10 Nm (7.5 ftlb.)

Connecting nut on fuel low-pressure line Tightening torque 30 Nm (22 ftlb.)

Preliminary work

Preliminary work

1. Drain refrigerant from the air conditioning system.

? 870317 Draining and filling refrigerant

2. Remove cowl panel cover.

? 508719 Removing and installing cowl panel cover

3. Remove transverse control arm cover.

? 852219 Removing and installing plenum panel cover

4. Remove rear profile seal.

? 553319 Removing and installing front lid seal

Removing rear profile seal

5. Drain coolant.

? 193817 Draining and filling coolant

Coolant drain plug

6. Remove underbody panelling.

? 519219 Removing and installing cover for front underbody

? 519319 Removing and installing cover for centre underbody

? 519419 Removing and installing cover for rear underbody

7. Remove the cardan shaft.

? 393519 Removing and installing rear cardan shaft

8. Remove brake calliper, but do not remove the brake line.

Suspend brake calliper in the wheel housing with a tie-wrap or a piece of wire.

? 473919 Removing and installing front brake calliper

? 473919 Removing and installing front brake calliper (PCCB)

9. Disconnect battery ground strap.

? 9X00IN Work instructions after disconnecting the battery

10. Remove front part of front wheel housing liner at both sides.

? 505619 Removing and installing front wheel housing liner

11. Remove front left wheel housing liner completely on vehicles with PDCC.

? 505619 Removing and installing front wheel housing liner

12. Lower the vehicle.

Removing engine

Removing engine

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.

Caution

Hot components

Risk of burns

? Let hot components cool down.

? Wear personal protective gear.

Information

These instructions describe how to remove and install the engine on vehicles with turbo engines with the maximum number of accessories and components.

Some of the steps described here may not be necessary on vehicles with naturally aspirated engines or on 2WD vehicles, for example, since these vehicles do not have certain accessories and components.

The slightly different illustrations between the naturally aspirated engine and the turbo engine show essentially the same tasks.

1. Remove engine wire harness in the plenum panel.

1.1. Release the relay fuse box ? Lifting up relay fuse box in the plenum panel at both sides, lift it up and disconnect the wire harness for the DME control unit in the plenum panel.

Lifting up relay fuse box

1.2. Release the connector on the DME control unit -Up arrow- and disconnect it -side direction arrow- .

Connector for DME control unit

1.3. Remove sealing sleeve with wire harness from the on-board panel. ? Sleeve with wire harness

Sleeve with wire harness

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

1.4. Place engine wire harness on the engine block.

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.

Notice

Aggressive fluids

Risk of damage to components and surfaces

? Do not spill fluids.

? If a component comes into contact with the fluid, wash the component or surface with water.

? Replace components that are already damaged.

2. Disconnect fuel low-pressure line.

2.1. Release and disconnect tank ventilation and vacuum line ? Tank ventilation and vacuum line at the connection point.

Tank ventilation and vacuum line

2.2. Put a cloth under the connection for the fuel low-pressure line to be disconnected in order to collect emerging fluid.

2.3. Release the fuel low-pressure line by countering with a wrench -direction arrow- and disconnect it. Counter at the centre piece and remove union nut on engine side.

Fuel low-pressure line

3. Remove upper torque support.

? 103719 Removing and installing torque support

4. Disconnect plug connections for oxygen sensors at the left and right.

4.1. Release and disconnect oxygen sensor plug connection -1- ( -arrow- ) at both sides.

Oxygen sensor plug connection

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

4.2. Place connecting cable for oxygen sensors on the engine.

5. Remove secondary-air pump.

5.1. Unscrew secondary-air pump and pull off hose. ? Removing secondary-air pump

Removing secondary-air pump

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

5.2. Place the secondary-air pump on the engine and secure it with a tie-wrap to prevent it from falling down.

6. Pull vacuum line off the vacuum pump at the connection piece -direction arrow- .

Vacuum pump hose

7. Release clip on coolant hoses at the plenum panel and remove them from the connection point at the plenum panel (cross panel). ? Removing coolant hoses

Removing coolant hoses

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

8. Pull breather hose off the bleeder valve -direction arrow- and set it down on the engine.

Breather hose

9. Remove positive cable at the jump-lead starting point.

9.1. Release flap on jump-lead starting point. ? Jump-lead starting point

Jump-lead starting point

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

9.2. Unscrew positive cable for battery at the jump-lead starting point ? Jump-lead starting point and set it down on the engine.

10. Disconnect hose for coolant reservoir underneath the valve cover (cylinders 5 to 8) -direction arrow- .

Hose for coolant reservoir

11. Drain hydraulic oil tank until empty.

? 430955 Replacing reservoir (PDCC)

? 489755 Replacing reservoir

12. Release and disconnect hose for hydraulic oil tank ? Hose for hydraulic oil tank .

Hose for hydraulic oil tank

13. Remove air box on throttle valve.

13.1. Remove design cover.

? 108319 Removing and installing engine cover (design cover)

13.2. Unscrew bayonet bolt at the air box -direction arrows- .

Bayonet bolt

13.3. Release and unplug connector for boost pressure sensor -position arrow- .

Connector for boost pressure sensor

13.4. Release hose clamps -position arrows- on the air box at both sides.

Hose clamps

13.5. Pull the air box out of the retaining clip, but leave the ventilation line (underneath the air box) for the crankcase fitted.

Information

Before setting down removed cables, lines and components, protect the top of the engine, the intake-air distributor and the design covers from scratches using a suitable cloth.

13.6. Set the air box down on the engine.

14. Disconnect wastegate control lines on both sides at the T-piece -direction arrow- .

Wastegate control line

15. Release and disconnect the clamp on the coolant hoses on the aluminium pipes for the thermostat housing at both sides. ? Coolant hoses

Coolant hoses

16. Secure coolant hoses together with the pressure hoses for the charge air cooler at the lock carrier with tie-wraps. ? Securing hoses

Securing hoses

17. To relieve the control arms, fit the safety hooks -position arrow- for the upper control arm at both sides.

Spring compressor VW 552

Safety hooks

18. Raise the vehicle halfway.

? 4X00IN Lifting the vehicle

19. Release and disconnect plug connection for rpm sensor at the wheel carrier on both sides -direction arrow- .

Connector for rpm sensor

20. Remove chassis components.

20.1. Remove fastening nuts -1- on the upper control arms at both sides -direction arrow- .

Fastening nuts on upper control arms

20.2. Remove fastening nut on connecting link at the spring strut on both sides -direction arrow- .

Fastening nut on connecting link

20.3. Loosen fastening nuts -1- on the lower control arm at both sides, but do not remove the bolt yet.

Fastening nuts on lower control arms

21. Left wheel housing: Remove fastening nut on power-steering pressure line holder and detach the retaining eyelet ? Fastening nut on holder .

Fastening nut on holder

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. Left wheel housing: Disconnect steel flexi-pipes on the PDCC valve block at the front.

22.1. Mark the installation position of the steel flexi-pipes -2- on the steel flexi-pipes themselves and on the valve block using a suitable paint marker -3- .

22.2. Unscrew cap screws on steel flexi-pipes -1- .

Steel flexi-pipes

23. Right wheel housing: Remove fastening screw -arrow- on the ground cable for the engine at the front right frame carrier.

Ground cable

24. Raise the vehicle fully.

? 4X00IN Lifting the vehicle

25. By carefully releasing the tension lock, disconnect the pressure hose on the charge air cooler at both sides ? Pressure hose on charge air cooler and leave the hose hanging freely.

Pressure hose on charge air cooler

26. Press the pressure hose aside at both sides, disconnect the hose clamp -position arrow- fitted behind it on the suction hose and pull off the hose -direction arrow- .

Suction hose

27. Remove ambient air valves at both sides.

Ambient air valve

27.1. Disconnect ambient air valve at the suction hose -1- on both sides.

27.2. Disconnect ambient air valve at the pressure hose -2- on both sides.

27.3. Disconnect vacuum line -3- on the ambient air valve on both sides and remove ambient air valve.

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.

28. Left side: Loosen steel flexi-pipe to the expansion hose ? Steel flexi-pipe to expansion hose .

28.1. Mark the installation position of the steel flexi-pipes on the steel flexi-pipes themselves and on the valve block using a suitable paint marker.

28.2. Loosen steel flexi-pipe to the expansion hose -direction arrow- and disconnect it.

Steel flexi-pipe to expansion hose

29. Left side: Remove return hose for hydraulic oil cooler.

29.1. Unscrew fastening screw -1- between the hose clamps.

29.2. Disconnect return hose -2- at the hydraulic oil cooler.

Return hose for hydraulic oil cooler

30. Remove reinforcement plate -1- .

Reinforcement plate

30.1. Unscrew fastening screws -2- .

30.2. Remove reinforcement plate -1- .

Notice

Opened refrigerant system for repairs.

Moisture penetrated into the refrigerant system.

Soiling of refrigerant circuit.

Saturation and subsequent disintegration of dryer.

If the dryer has disintegrated, the dryer, 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 dryer.

Information

After disconnecting hoses, close off all openings immediately using commercially available rubber stoppers.

When fitting parts, do not remove stoppers until shortly before installation. Likewise, do not remove the protective foil from the dryer until just before installation. The dryer absorbs moisture from the air and is then useless.

31. Remove air-conditioning compressor accessories.

Flexible-head socket wrench, a/f 10 9824/1

Torx Micro Bit T45 9824/3

31.1. Remove intake pipe and pressure line from the air conditioning compressor. ? Air-conditioning compressor lines

Air-conditioning compressor lines

31.2. Loosen fastening screw -1- on air-conditioning line holder.

Air-conditioning line holder (at the front of the supporting frame)

31.3. Remove air-conditioning line holder from the guide -2- .

32. Remove PDK wiring harness.

32.1. Remove fastening screws -position arrows- on heat protection panel for PDK wiring harness on the transmission.

Heat protection panel for PDK wiring harness

32.1.1. Remove heat protection panel for PDK wiring harness.

32.2. Release and unplug the connectors on the end of the PDK wiring harness at the transmission -1- ( -2- ) and loosen the retaining clip -3- .

Connectors on PDK wiring harness

32.3. Loosen the retaining clips on the PDK wiring harness and remove the PDK wiring harness from the clips -position arrows- .

Retaining clips on PDK wiring harness

33. Remove parking lock cable.

? 371319 Removing and installing locking cable

33.1. Disconnect the parking lock cable from the ball joint on the transmission.

33.2. Lift the parking lock cable out of the support and secure it towards the top.

34. Remove heat protection panel -1- between the universal joint for the steering gear and the primary catalytic converter.

Heat protection panel

34.1. Remove fastening screws -2- .

34.2. Remove heat protection panel -1- .

Information

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 the centre position after installation of the steering gear ? 945019 Removing and installing steering column switch

35. Remove universal joint -1- .

Removing universal joint

35.1. On vehicles with Servotronic: Pull off connector -3- .

35.2. Loosen holder on Servotronic connector cable and set the cable aside.

35.3. Loosen clamping screw -2- .

35.4. Slide universal joint -1- and lower part of steering column upwards.

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!

36. Loosen supply and return hose for the ATF transmission fluid cooler -direction arrows- and drain the fluid.

Supply and return hose for transmission fluid cooler

Information

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.

37. Place elevating platform Master Gear unit elevating platform WE 1206 under the vehicle and move all assembly drivers -A, B, C, D, E, F- to the same height at the correct position.

Overview of assembly drivers

For specific tightening torques and further details on positioning, see the operating instructions provided with the assembly fixture: Assembly fixture for Porsche Panamera Master Gear 1.0 elevating platform

Legend for assembly drivers and supports Position

Designation

Explanation

A

Transmission bracket

For mounting on the transmission mount.

B

Assembly driver on cross panel

For mounting on the cross panel.

C

Wheel hub holder

Secures the axles and prevents them from falling out.

D

Steering knuckle bracket

In conjunction with the wheel hub holder C, this protects the axles and spring struts from damage.

E

Assembly driver on front-axle carrier

For mounting on the rear of the front-axle carrier.

F

Front-axle carrier support

For mounting on the front of the front-axle carrier.

38. Get the elevating platform ready and move it to the jacking points on the front axle (supporting frame and even transmission mount). Set the heights of the drivers and supports and ensure solid contact.

39. Remove bolts on lower control arms.

39.1. Raise the elevating platform slightly in order to relieve the pressure on the bolts on the lower control arms.

39.2. Pull out bolt on the lower control arm on both sides -direction arrow- .

Bolts on lower control arms

40. Remove the safety hooks -position arrow- for the upper control arm on both sides.

Safety hooks

41. Detach front-axle carrier.

Marking and fastening screws on front-axle carrier

41.1. Mark the position of the contact points of the front-axle carrier on the longitudinal members -position arrow- on both sides.

41.2. Remove fastening screws securing front-axle carrier to the longitudinal member on both sides.

42. Remove fastening screws -position arrows- securing the anti-roll bar mount to the supporting plate on both sides.

Fastening screws on supporting plate

43. Remove transverse struts.

Removing struts (right side shown here)

43.1. Right side: Press rear wheel housing cover -1- down -direction arrow- and remove the transverse strut -2- between the supporting plate and door sill.

43.2. Left side: Remove transverse strut between the supporting plate and door sill.

44. Fit wheel hub holder -1- at both sides using assembly pins -2- on the wheel hub.

Wheel hub holder (shown here on steel brake disc)

45. Remove the fastening screws -position arrows- on the rear transmission mount.

Fastening screws on transmission mount

Information

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.

Information

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.

46. Remove the engine.

46.1. Gradually lower the elevating platform Master Gear unit elevating platform WE 1206 and engine/transmission unit.

46.2. Gradually guide the air-conditioning lines ? Air-conditioning line along with your hand.

Air-conditioning line

46.3. Move engine out from under the vehicle using the elevating platform.

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 suitable protective measures (e.g. 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.

Saturation and subsequent disintegration of dryer.

If the dryer has disintegrated, the dryer, 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 dryer.

Information

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 the centre position after installation of the steering gear ? 945019 Removing and installing steering column switch

Information

The tightening specifications for the basic engine are stored centrally. ? 1001IN Tightening torques, tightening sequences, assembly overviews. Tightening torques and assembly instructions for other affected 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 elevating platform.

1.2. Position the wheels of the elevating 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 line along with your hand.

Air-conditioning line

1.5. Fit the parking lock cable at half height (easier to access).

? 371319 Removing and installing locking cable

1.5.1. Pull the parking lock cable down and engage it in the support.

1.5.2. Fit the 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

Marking and fastening screws on front-axle carrier

2.1. By adjusting the position of the elevating platform slightly, move to the marking -position arrow- for the contact points for the front-axle carrier on the longitudinal members.

2.2. Fit the fastening screws securing front-axle carrier to the longitudinal member on both sides.

3. Fit the fastening screws -position 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 -position arrows- securing the anti-roll bar mount to the supporting plate on both sides.

For tightening torques and other details, see Chassis

Fastening screws on supporting plate

5. Fit transverse struts -2- .

For tightening torques and other details, see Chassis.

Removing struts (right side shown here)

5.1. Right side: Press rear wheel housing cover -1- down -direction 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 -direction 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 elevating platform and remove assembly pins -2- on the wheel hub.

Wheel hub holder (shown here on steel brake disc)

8. Lower the elevating platform and push it 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 suitable protective measures (e.g. gloves, safety goggles, oil binding material)

? Collect emerging ATF!

9. Fit supply and return hose for the ATF transmission fluid cooler -direction arrow- .

For tightening torques and other details, see: ? 386019 Removing and installing ATF cooler

Supply and return hose for transmission fluid cooler

Information

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 the centre position after installation of the steering gear ? 945019 Removing and installing steering column switch

10. Fit universal joint -1- .

For tightening torques and other details, see: ? 481519 Removing and installing steering column

Fitting universal joint

10.1. Pull universal joint -1- and lower part of steering column downwards -direction arrow- .

10.2. Fit clamping screw -2- .

10.3. On vehicles with Servotronic: Plug in connector -3- .

10.4. Fit holder on cable for 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 wiring harness.

12.1. Plug in the connectors on the end of the PDK wiring harness at the transmission -2- ( -1- ) and fit the retaining clip -3- .

Connectors on PDK wiring harness

12.2. Fit retaining clips -position arrows- for the PDK wiring harness.

Retaining clips on PDK wiring harness

12.3. Guide in heat protection panel for PDK wiring harness and fit fastening screws -position arrows- on the transmission.

Heat protection panel for PDK wiring harness

Notice

Opened refrigerant system for repairs.

Moisture penetrated into the refrigerant system.

Soiling of refrigerant circuit.

Saturation and subsequent disintegration of dryer.

If the dryer has disintegrated, the dryer, 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 dryer.

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

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 -direction arrow- by tightening the hose clamps -position 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 -position arrow- on the ground cable for the engine at the front right 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 themselves and on the valve block during removal using a paint marker -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 at the spring strut on both sides -direction arrow- .

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 the coolant hoses on the engine block at both sides. ? Coolant hoses

Coolant hoses

27. Connect wastegate control lines on both sides at the T-piece -direction arrow- .

Wastegate control line

28. Fit air box on throttle valve.

28.1. Fit hose clamps -position arrows- on the air box at both sides.

Hose clamps

28.2. Fit bayonet bolt at the air box -direction arrows- .

Bayonet bolt

28.3. Plug in connector for boost-pressure sensor -position arrow- .

Connector for boost pressure sensor

28.4. Install design cover.

? 108319 Removing and installing engine cover (design cover)

29. Fit hose for hydraulic oil tank. ? Hose for hydraulic oil tank

Hose for hydraulic oil tank

30. Fit hose for coolant reservoir -direction 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

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

Notice

Aggressive fluids

Risk of damage to components and surfaces

? Do not spill fluids.

? If a component comes into contact with the fluid, 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 union nut on engine side. ? Tightening torque: 30 Nm (22 ftlb.) ? Fuel low-pressure line

Fuel low-pressure line

38. Install wiring 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 the relay fuse box in the plenum panel at both sides, lift it up ? Lifting up relay fuse box and route wire harness for the 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

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

2. Install front part of front wheel housing liner at both sides.

? 505619 Removing and installing front wheel housing liner

3. Install brake calliper on both sides.

? 473919 Removing and installing front brake calliper

? 473919 Removing and installing front brake calliper (PCCB)

4. Install cardan shaft.

? 393519 Removing and installing rear cardan shaft

5. Install underbody panelling.

? 519219 Removing and installing cover for front underbody

? 519319 Removing and installing cover for centre underbody

? 519419 Removing and installing cover for rear underbody

6. Install rear profile seal. ? 553319 Removing and installing front lid seal

7. Install transverse control arm cover.

? 852219 Removing and installing plenum panel cover

8. Install cowl panel cover.

? 508719 Removing and installing cowl panel cover

9. Connect battery ground strap.

? 9X00IN Work instructions after disconnecting the battery

10. Fill in coolant.

? 193817 Draining and filling coolant

11. Fill in refrigerant for the air conditioning system.

? 870317 Draining and filling refrigerant

12. Fill the hydraulic oil tank.

? 430955 Replacing reservoir (PDCC)

? 489755 Replacing reservoir

13. Bleed power steering.

? 480201 Checking hydraulic fluid (fluid level)

14. Check ATF level.

? 370235 Checking and topping up ATF

15. Check engine-oil level.

? 170101 Checking engine-oil level

16. Perform suspension alignment.

? 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.

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