8.5.2

Loosen and unscrew fastening screws  Upper air guide for charge-air cooler -3for left and right air guide.

8.5.3

Unclip left and right air guide  Upper air guide for charge-air cooler -1- at the
retaining lugs  Upper air guide for charge-air cooler -4- and pull them up off the
charge-air cooler.

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8.6

Remove lower air guide at the right  Lower
air guide for charge-air cooler -2- for the
charge-air cooler. To do this, loosen and
unscrew the fastening screw  Lower air
guide for charge-air cooler -1- and pull the air
guide to the side and off the charge-air cooler
 Lower air guide for charge-air cooler
-Arrow-.

Lower air guide for charge-air cooler
8.7

Lever off and remove front fixing clip 
Loosening charge-air cooler at the holder -1and rear fixing clip  Loosening charge-air
cooler at the holder -2- for the charge-air
cooler at the holder  Loosening charge-air
cooler at the holder -3-. Then, remove the
charge-air cooler by pulling it up out of the
engine compartment. The holder remains on
the vehicle initially.

Loosening charge-air cooler at the holder
8.8

9

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Remove holder for charge-air cooler. To do
this, push the fastening pin  Removing
holder for charge-air cooler -1- out to the rear
from the engine compartment using a ring
wrench  Removing holder for charge-air
cooler -2- (a/f 8 mm)  Removing holder for
charge-air cooler -Arrow-.
Pull out the fastening pin fully and remove the
holder from the engine compartment.

Loosen connecting link at the left and right on the
anti-roll bar.
For instructions, see:

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1

 Workshop Manual '429119 Removing and installing connecting link for anti-roll bar'
 Workshop Manual '429119 Removing and installing connecting link for anti-roll bar (PDCC)'
WARNING
Chassis setup changed after loosening the eccentric adjusting screws
•

Uncontrollable or unexpected vehicle handling

•

Increased tyre wear



Do not loosen eccentric adjusting screws for trailing arm when removing the rear-axle cross member.



If the eccentric adjusting screws were loosened, perform a complete suspension alignment and
adjust the chassis to the specified values.



Marking the adjusting screws and setting them afterwards to the previously applied marking is not
permitted.
10 Remove rear-axle cross member  Removing rear-axle cross member with lower trailing arm -1together with the lower trailing arms  Removing rear-axle cross member with lower trailing arm
-2-.
Do not loosen the eccentric adjusting screws for the camber at the threaded joint of the trailing
arm on the cross member, but only loosen the threaded joint  Removing rear-axle cross member
with lower trailing arm -3- on the lower trailing arm at the wheel carriers.
However, if the threaded joint of the trailing arm on the rear-axle cross member is
loosened, complete suspension alignment must always be performed.

Removing rear-axle cross member with lower trailing arm
For instructions, see:
 Workshop Manual '420619 Removing and installing rear axle carrier'
 Workshop Manual '421119 Removing and installing trailing arm'

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Information

•

The inner fastening screws for the rear-axle cross member cannot be removed initially
when the trailing arms are installed. These can only be removed when the rear-axle cross
member is removed and the trailing arms are pressed down. Get another mechanic to help you
with this if necessary.

•

The anti-roll bar is removed together with the rear-axle cross member. Only the connecting links
on the anti-roll bar must be loosened.

11 Only for vehicles with roll stabilization PDCC (I-no. 1P7): Loosen PDCC lines and valve block at
the rear.
11.1

Loosen and unscrew fastening screws 
Valve block mounting (rear) -2- for PDCC
valve block at the rear  Valve block
mounting (rear) -1-.
Do not loosen the PDCC lines on the valve
block.

Valve block mounting (rear)
11.2

Unscrew holder  Holder for PDCC lines
(picture shows right side) -1- at the left and
right for PDCC lines. To do this, loosen and
unscrew the fastening screws  Holder for
PDCC lines (picture shows right side) -2-.

11.3

Leave PDCC valve block and holder with
connected lines hanging down.

12 Lower the engine by 90 to 100 mm.
Contrary to the instructions in the Workshop
Manual, do not drain and open the refrigerant
circuit.
Holder for PDCC lines (picture
Instead, lower the engine as far as required until the
shows right side)
refrigerant lines on the right-hand side in the engine
compartment at the top are touching the body/longitudinal member. Get a second mechanic to
monitor this during the lowering process if necessary.
For instructions, see  Workshop Manual '100109 Lowering the engine'.

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Replacing engine mounts and retrofitting caps
Information
The procedure for removing and installing is described on one side as an example, but both engine
mounts must be replaced.
The procedure for removing and installing both engine mounts is practically identical.
Work Procedure: 1

Remove heat shield  Heat shield on rear bracket
(left side) -3- on the rear bracket.
To do this, loosen and unscrew the fastening screws
 Heat shield on rear bracket (left side) -1- and
fastening nut  Heat shield on rear bracket (left side)
-2-.

Heat shield on rear bracket (left side)
2

Release and disconnect electric plug connection 
Plug connection for PADM engine mount -1- on the
engine mount.

3

Remove engine mount.

Plug connection for PADM engine mount
Information
The engine mounts must be installed perfectly with a defined distance between them
in the vehicle for optimum functioning so that the mounts are not too tight after installing the
engine.
However, it is not possible to measure the distance between the engine mounts
when the engine is lowered.
It is important, therefore, to mark the position of the engine mounts before removal and
restore this position during subsequent installation.

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3.1

Mark the position of the engine mount

 Removing engine mounting -1- on the
bodyshell.
There is a corresponding notch  Removing
engine mounting -Arrows- at the front and
rear in the engine mount housing when viewed
in direction of travel.
3.2

Loosen and unscrew fastening screws

 Removing engine mounting -2-. Then,
remove the engine mount.

Removing engine mounting
4

Install the cap to be retrofitted on the new engine
mount.
For this purpose, thread the electric plug connection
through the cap  Installing cap -1- and then push
the cap as far as it will go onto the engine mount 
Installing cap -2-.

Installing cap

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Part No.

Designation

Qty.

992199534A

Cap

2 ea.

992199384A

Engine mount

2 ea.

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Install the new engine mount with installed cap.
5.1

Position new engine mount  Installing
engine mounting -1- in installation position on
the bodyshell.
Screw in fastening screws  Installing engine
mounting -2- hand-tight, but do not tighten
them initially.

Installing engine mounting
Part No.

Designation

Qty.

PAF107838

Hexagon-head bolt, M8 x 50

8 ea.

Information
The engine mounts must be installed perfectly with a defined distance between them
in the vehicle for optimum functioning so that the mounts are not too tight after installing the
engine.
However, it is not possible to measure the distance between the engine mounts when
the engine is lowered.
It is important, therefore, to restore the position of the engine mounts marked before
removal during installation.
5.2

Align engine mount according to the marking applied earlier  Installing engine mounting
-Arrows- on the bodyshell.
Permissible deviation: max. +/- 1 mm

5.3

Screw in fastening screws  Installing engine mounting -2- for engine mount and tighten
using the two-step tightening procedure.
•
•

6

Initial tightening 16 Nm (12 ftlb.)
Final tightening +30°

Connect electric plug connection to the engine mount until you hear and feel the connector
engaging.

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Install heat shield  Heat shield on rear bracket (left side) -3- on the rear bracket.
To do this, position the heat shield and screw in and tighten the fastening screws  Heat shield on
rear bracket (left side) -1- and fastening nut  Heat shield on rear bracket (left side) -2-.
•
•

Fastening screws: Tightening torque 2.5 Nm (1.75 ftlb.)
Fastening nut: Tightening torque 2.5 Nm (1.75 ftlb.)

Heat shield on rear bracket (left side)

Concluding work
Work Procedure: 1

2

Raise the engine to installation position and secure it  Workshop Manual '100109 Lowering the
engine'.
Only for vehicles with roll stabilization PDCC (I-no. 1P7): Secure PDCC lines and valve block at
the rear.
2.1

Lift PDCC valve block and holder with connected lines into installation position and position
them.

2.2

Screw in and tighten fastening screws 
Valve block mounting (rear) -2- for PDCC
valve block at the rear  Valve block
mounting (rear) -1-.
Tightening torque 10 Nm (7.5 ftlb.)

Valve block mounting (rear)

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Secure holder  Holder for PDCC lines
(picture shows right side) -1- at the left and
right for PDCC lines. To do this, screw in and
tighten the fastening screws  Holder for
PDCC lines (picture shows right side) -2-.
Tightening torque 10 Nm (7.5 ftlb.)

Install rear axle carrier together with the lower trailing
arms.
For instructions, see:
 Workshop Manual '420619 Removing and
installing rear axle carrier'
 Workshop Manual '421119 Removing and
installing trailing arm'

Holder for PDCC lines (picture
shows right side)

Part No.

Designation
– Use

Qty.

PAF008735

Hexagon-head bolt, M12 x 1.5 x 95
– Rear-axle cross member to outer side
panel

2 ea.

PAF008673

Hexagon-head bolt, M12 x 1.5 x 110
– Rear-axle cross member to inner side
panel

2 ea.

PAF008674

Hexagon-head bolt, M12 x 1.5 x 105
– Lower trailing arm to rear wheel carrier

2 ea.

PAF909664

Hexagon collar nut, M12
– Lower trailing arm to rear wheel carrier

2 ea.

Secure connecting link at the left and right on the anti-roll bar.
For instructions, see:
 Workshop Manual '429119 Removing and installing connecting link for anti-roll bar'
 Workshop Manual '429119 Removing and installing connecting link for anti-roll bar (PDCC)'
Part No.

Designation
– Use