31 10 001 Completely Removing and Installing Front Axle With Engine and Transmission

31 10 001 Completely Removing and Installing Front Axle with Engine and Transmission (N63 Hybrid Car)

Special tools required:






Warning!
High-voltage system - danger to life!
The luggage compartment must be empty to prevent the vehicle from tipping off of the vehicle hoist.
When the front axle with engine and transmission are removed, the vehicle can easily tip backward.






Warning!
The following points must be strictly observed prior to starting work:
- Disconnect high-voltage system from power
- Observe safety information for working with hybrid cars.






Important!
Removal weight approx. 250 kg to 450 kg.
Check payload of vehicle and empty if necessary
Load front footwell with sandbags if necessary, approx. 200 kg.
Follow safety information of aggregate table!






Necessary preliminary work:
- Position vehicle on vehicle hoist so its weight is centered.
- Disconnect the battery
- Move engine compartment lid into service position
- Suction off air conditioning.
- Remove and install power electronics box.
- Remove both intake silencer housings.
- Remove charge air cooler expansion tank.
- Remove coolant expansion tank.
- Remove fan cowl with electric fan.
- Remove auxiliary water pump for charge air cooler.
- Remove complete propeller shaft.
- Remove front right wheel arch cover.
- Release feed and return lines for engine oil cooler
- Remove brake caliper on left and right
- Detach steering shaft from steering box
- Remove both covers for steering box.






Release vacuum line (3) for brake servo.






Unlock coolant hose (1) and detach from coolant pipe.






Release engine wiring harness from electronics box and secure on engine against falling off.
Unlock and detach all connectors (1) on DME control unit.
Unlock plug on electronics box fan and disconnect.
Unlock and detach terminal strip (2).
Unlock all plugs on plug strip (3) and detach.
Unlock plug strip (3) and remove towards top.






Release screws and remove retaining bracket (1).
Unlock upper part (2) of partition seal in direction of arrow and remove.
Release grommets (3) for wiring harnesses from lower section of partition seal and from electronics box.

Installation note:
Make sure grommets are correctly seated so as to prevent ingress of moisture.






Unlock and detach vacuum line (1) from vacuum pump.






Release screws (1).
Detach line.
Tightening torque 64 53 5AZ.

Installation note:
Replace sealing rings and moisten with refrigerant fluid.






Unlock and disconnect fuel delivery line (1), seal off with special tool 13 5 160.
Seal off fuel delivery line (2) with special tool 13 5 162.






Release nut and remove screw (3).
Fix brake caliper (1) with a suitable auxiliary materials (2).

Installation note:
Keep wishbone to swivel bearing connection clean and free from oil and grease.

Note direction of insertion of screw.
Screw must rest correctly in groove of ball stud.
Replace self-locking nut.
Tightening torque: 31 12 6AZ






Release nut (1) and remove screw (2).

Installation note:
Replace screw and nut.

Note direction of insertion of screw.
Tighten down screw connection in normal position.
Tightening torque 31 12 3AZ.
Detach plug connection of speed sensor at front left and right.






Turn steering wheel.
Use two mounting levers on both sides to unlock the drive shaft of the front axle differential.






Release screw (1).






Release screw (1).
Disconnect A/C line (2).

Installation note:
Replace O-ring.






Remove expansion tank.
Disconnect coolant hose (1) from auxiliary water pump (2).






Slacken nut (1).
Release holder (2) from support plate (3).






Disengage engine oil pipe (1) from bracket (2).

Important!
Coordinate determination always begins at the top.






Position engine assembly on table top A.
Position transmission on table top B.
Table top is adjustable in a longitudinal direction (see arrow).






Structure of all-wheel drive vehicle table lift.
Position retaining elements (20) with fixture (40) on table top B for cross member at coordinates 2/2.

Position retaining elements (20) with fixture (50) on table top B for cross member at coordinates 2/7.

Position an additional retaining element (20) with fixture (80) on table top B under transmission at coordinates 4/4 and 7/5.

Position retaining elements (20) with fixtures (60) on table top A for front axle support at coordinates 2/2 -1/7 - 6/2 and 6/7.

Position fixture (10) on table top A for swivel bearing at coordinates 3/1 and 4/8.






Note:
Possible mounting points for front axle support and transmission.

Note position (1 to 4).
Graphic diagram (E70).






Secure fixture of swivel bearing (1) on brake disc with wheel studs (2).
Secure adjusting screw (3).






Release screws.
Tightening torque, 22 32 4AZ.






Release screws (1 and 2).

Installation note:
Tighten down first screws (1) and then screws (2).






With lift truck 81 22 2 184 136 and the aid of another person, carefully remove, from below, engine with transmission in front axle support combination.

Note:
Graphic diagram (E72 hybrid).






Installation note:
The inclination of the table lift (1) can be adjusted using adjusting screws (2).





Note:
Reassemble the vehicle.

��':