Removing engine

WARNING: High-voltage system.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!

All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
For additional information see:
61 00... SAFETY INFORMATION ON HANDLING HYBRID CARS .
For additional information see:
61 25... NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

WARNING: Hot surfaces.
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Car may slip off the vehicle hoist where components are supported.
Danger! Immobilization period-threatening injuries!

Secure the vehicle hoist against lowering and lifting.

WARNING: Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!

Ensure there is a specific weight compensation on the car.

WARNING: Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly.
Danger! Immobilization period-threatening injuries!

Observe safety instructions on raising the vehicle using a vehicle hoist.
For additional information see: 00... RAISE THE VEHICLE USING A VEHICLE LIFT .

WARNING: Working on 12 V electrical system.
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

CAUTION: On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!

Wear suitable personal protective equipment.
Before performing any installation work, allow cooling system to cool down to less than 40°C.
Note warnings on cylinder head cover.

NOTE: RISK OF DAMAGE
Engine damage due to missing motor oil.
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train,

After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
It is imperative you observe the repair notes for cylinder head or engine replacement.
For additional information, see: REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Preliminary work:

Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
Refer to SUCTION THE AIR CONDITIONING
Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
Refer to REMOVING THE ACOUSTIC COVER (2018-2020) or REMOVING THE ACOUSTIC COVER (2021-2022) .
Refer to REMOVING THE SEAL FOR THE HOOD REAR .
Refer to REMOVING THE COVER OF THE REAR RIGHT ENGINE COMPARTMENT .
Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT
Refer to REMOVING LEFT AND RIGHT WIPER ARM .
Refer to REMOVING THE COWL COVER .
Refer to REMOVING TRAILING LINK AT SPRING BOLT .
Refer to REMOVING THE CENTER COWL UPPER PART .
Refer to LOOSENING HIGH-VOLTAGE CABLES ON THE ELECTRICAL MACHINE ELECTRONICS .
Refer to REMOVING ACOUSTIC COVER AT REAR (2018-2020) or REMOVING ACOUSTIC COVER AT REAR (2021-2022) .
Refer to REMOVING LEFT SEALING FRAME .
Refer to REMOVING THE CENTER BULKHEAD LOWER PART
Refer to REMOVING THE COVER ON LEFT AND RIGHT IN THE ENGINE COMPARTMENT AT THE TOP .
Refer to REMOVING THE LEFT AND RIGHT FRONT-END STRUT
Refer to REMOVING IGNITION COILS (2018-2020) or REMOVING ALL IGNITION COILS (2021-2022) .
Refer to REMOVING FUEL DELIVERY LINE (2018-2020) or REMOVING FUEL DELIVERY LINE (2021-2022) .
Refer to REMOVING RESONATOR .
Refer to REMOVING CLEAN AIR PIPE (2018-2020) or REMOVING CLEAN AIR PIPE (2021-2022) .
Refer to REMOVING CHARGE AIR LINE (2018-2020) or REMOVING CHARGE AIR LINE (2021-2022) .
Refer to REMOVING THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT (2018-2020) or REMOVING THE ACOUSTIC COVER FOR THE ENGINE AT THE FRONT (2021-2022) .
Refer to REMOVING THE DRIVE BELT FOR COOLANT PUMP (2018-2020) or REMOVING THE DRIVE BELT FOR COOLANT PUMP (2021-2022) .
Refer to REMOVING THE LAMBDA OXYGEN SENSOR (2018-2020) or REMOVING THE LAMBDA OXYGEN SENSOR (2021-2022) .
Refer to REMOVING THE DME CONTROL UNIT (2018-2020) or REMOVING THE DME CONTROL UNIT (2021-2022) .
Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) .
Refer to REMOVING CONTROL UNIT BRACKET (2018-2020) or REMOVING CONTROL UNIT BRACKET (2021-2022) .
Refer to REMOVING THE FRONT LEFT AND RIGHT WHEELS .
Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY ON THE LEFT AND RIGHT
Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD (FRONT STIFFENING PLATE) .
Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
Refer to REMOVING REAR THRUST FIELD .
Refer to REMOVING REAR UNDERBODY PROTECTION .
Refer to REMOVING THE REAR SECTION OF THE WHEEL ARCH COVER ON THE FRONT LEFT AND RIGHT .
Refer to IF INSTALLED: REMOVING THE TORSION STRUT ON THE RIGHT AND LEFT WHERE REQUIRED .
Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
Refer to REMOVING THE REAR AXLE COVER .
Refer to REMOVING COMPLETE EXHAUST SYSTEM .
Refer to REMOVING CATALYTIC CONVERTER (2018-2020) or REMOVING CATALYTIC CONVERTER (2021-2022) .
Refer to DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM (2018-2020) or DRAINING THE COOLANT FROM THE HIGH-TEMPERATURE COOLING SYSTEM (2021-2022) .
Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM (2018-2020) or DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM (2021-2022) .
Refer to REMOVING TANK VENT VALVE (2018-2020) or REMOVING TANK VENT VALVE (2021-2022) .
Refer to REMOVING INTAKE PLENUM (2018-2020) or REMOVING INTAKE PLENUM (2021-2022) .
Refer to REMOVING THE HEAT SHIELDS .
Refer to PARTIALLY LOOSENING THE PROP SHAFT
RWD vehicles: Refer to REMOVING TRANSMISSION CROSS-MEMBER .
AWD vehicles: Refer to REMOVING TRANSMISSION CROSS-MEMBER .
Refer to REMOVING AUTOMATIC TRANSMISSION (GA8HP75HZ) .
Refer to INSTALLING THE SPECIAL TOOL ON THE CYLINDER HEAD .

Further information is available.

WARNING: Vehicle may slip off the vehicle hoist if the vehicle hoist is handled incorrectly.
Danger! Immobilization period-threatening injuries!

Observe safety instructions on raising the vehicle using a vehicle hoist.
For additional information see: 00... RAISE THE VEHICLE USING A VEHICLE LIFT .

WARNING: Car may slip off the vehicle hoist if the weight is distributed unevenly.
Danger! Immobilization period-threatening injuries!

Ensure there is a specific weight compensation on the car.

WARNING: Working on 12 V electrical system.
Risk of short circuits! Risk of fire!

Make sure that there is no charger connected to the jump start terminal in the engine compartment.
Detach battery ground lead from battery.
For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

WARNING: Contact with hazardous fluids.
Hazardous to health!

Note and follow safety instructions on containers.
Conduct all work in appropriate personal protective equipment only.

CAUTION: Heavy component
Heavy components can lead to injury or damage.

Remove and install heavy components with the aid of another person/other persons.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Prepare the special tool 2 220 718.

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Prepare special tool 0 490 567 (11 0 020).

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Remove the cover (2) from the latch mechanisms (1).
Remove cover (2) in direction of arrow towards top.

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Release nut (1).
Remove the positive battery cable (2) and set it aside.
Guide the positive battery cable (2) out of the clamp (3) and lay to one side.

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Loosen clamp (1).
Unlock and release lock (2).
Glide the fuel feed line (3) out and set it aside.
Catch and dispose of escaping fuel.
Unlock and disconnect the tank ventilation line (4).

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Unlock and disconnect the vacuum line (1).

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Unlock and release the coolant lines (1).
Catch and dispose of escaping coolant.

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Unlock and release the coolant line (1).
Unlock and release the coolant line (2).
Unlock and release the coolant line (3).

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Unlock and loosen coolant line (1).
Feed oil coolant line (1) and remove.

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Remove coolant hoses (1) from the holder (2).
Remove the holder (2).

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Open the holder (arrow) and remove the coolant hose (1).
Release the screw (2).
Release the screw (3).
Unlock and disconnect the high-voltage connector (4).
Set the high-voltage cable (5) aside.

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CAUTION:
Residual pressure in the heating and air conditioning system.
Injury hazard!
- Wear safety goggles and protective gloves when disconnecting the refrigerant line.
- Close the refrigerant lines with seal plugs.
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Release the screw (1).
Feed out refrigerant line (2) and place to one side.
Release the screw (3).
Feed out refrigerant line (4) and place to one side.
CAUTION:
Residual pressure in the heating and air conditioning system.
Injury hazard!
- Wear safety goggles and protective gloves when disconnecting the refrigerant line.
- Close the refrigerant lines with seal plugs.
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Release the screw (1).
Feed out and remove pressure line (2) between the air conditioning condenser and the air conditioning compressor.
Unlock and release the coolant line (1).
Unlock and release the coolant line (2).
Catch and dispose of escaping coolant.

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Unlock the lock (1).
Feed out coolant line (2) and remove.
Unlock lock (3).
Unlock the clamp (4) and release it.
Feed coolant line (5) out of clamp (4) and place to one side.

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Unlock and release the coolant line (1).

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Release the bolts (1) on the front side support (2).

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Unlock and release transmission oil line (1).
Unlock and release transmission oil line (2).
Catch and dispose of escaping transmission oil.

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Loosen screw (1).
Guide out and remove manifold support (2).

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Detach vacuum hose (1) from vacuum line (2) in direction of arrow.

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Keep all the standard tools ready.

Number	Description
1	Standard torque wrench
2	Swiveling extension
3	External Torx E14

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Position suitable tool (1).

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Release screw (1) of the left engine mount with standard tool (2) sideways.

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Release screw (1) on the right engine mount from the top with a commercially available tool.

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Hook the special tool 0 490 567 (11 0 020) at the special tool 2 220 718 (2).
Hook the special tool 0490 567 (11 0 020) to engine mounting bracket (1).
Hook the special tool 0 490 567 (11 0 020) to special tool 2 459 012.
Feed out the combustion engine with the special tool 2 220 718 (2) and remove it.

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