Engine/Transmission, Removing
Engine/transmission, removing
Special tools:
999 5722 Wrench 999 5722 Wrench
999 5259 SEPARATOR 999 5259 Separator
999 5972 FIXTURE 999 5972 Fixture
Preparation
Remove:
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
- the air cleaner housing assembly, including intake manifold.
Lift up the power steering fluid reservoir and place it on the engine.
Loosen the expansion tank cap.
Note! Make sure that power steering fluid does not leak out through the vent holes in the filler cap.
Remove the splash guard under the engine.
Disconnect the connectors for the heated oxygen sensors. Remove the wiring from the clips and tie straps.
Connect a hose to the engine coolant drain cock.
Drain the coolant into a clean receptacle.
Close the cock.
Remove:
- the screw of the engine stabilizer brace mounting on the engine.
- the cross stay between the suspension turrets
- the plastic charge air pipe. Place to one side.
- the plastic intake pipe. Put it to one side.
Remove:
- the intake and charge air pipes from the turbocharger. Plug the openings of the turbocharger.
- the heat deflector plates.
- the upper heated oxygen sensors (HO2S).
- the engine wiring's ground cable.
- the cover from the control module box.
- the control modules. Use mounting bracket 999 5722 Wrench 999 5722 Wrench.
- the intermediate section of the control module box.
Pry out the connector plate from the lower section of the control module box and pull the connectors of the engine and transmission wiring from the plate.
Place the engine and transmission wiring on top of the engine.
- the screw of the upper torque rod from the engine.
- the engine stabilizer brace from the suspension turret.
- the engine cable from the positive terminal at the left suspension turret.
- the brake vacuum hose from the intake manifold.
- the mechanical transmission cable from the transmission.
Note! Take care that the cable does not break or crack.
Detach the hose running from the radiator to the expansion tank.
Lift up the tank and place it on the engine.
Remove
- the hoses of the heating system.
- the upper radiator hose.
- the upper oil cooler hose to the transmission.
Note! Protect the openings against dirt.
Remove
- the EVAP canister purge valve from the mounting on the fan shroud.
- the connector from the EVAP canister purge valve.
- the supply hose between the turbocharger pipe and the charge air cooler (B6xx4T only).
Detach the intake manifold from the charge air cooler.
- the connector of the pressure monitor for the dryer bottle.
- the connector to the electric cooling fan.
- the wiring from the terminal. Place it over the engine.
Detach the fan shroud from the wiring.
- the fan shroud from the radiator.
Relieve tension on the auxiliaries belt tensioner and hang the belt from the power steering pump.
Unplug the connector of the AC compressor's electromagnetic clutch.
Remove the four screws holding the AC compressor in the engine. Start with the lowest screw.
Note! Take care that the pipe does not break or crack when the two upper screws are loosened.
Remove the AC compressor and bind it up on the front cover plate.
Remove the nuts. Disconnect the front exhaust pipe from the turbocharger (TC).
Separate the exhaust system at the flange behind the rear catalytic converter.
Remove the center SIPS member.
Disconnect the brake pipe from the clips on the front SIPS member.
Remove the screws of the front SIPS member.
Slide the three-way catalytic converter (TWC) (with the heat deflector plate) back and then lower it.
Remove the panel below the dashboard on the driver's side.
Turn the steering wheel to gain the best possible access to the steering shaft nut.
Remove the ignition key so that the steering wheel lock is activated.
Undo the joint from the lower steering shaft. Cut the cable tie and remove the bushing from the boot.
Note! Do not shift the front wheel's position until it is measured against, for example, the subframe. Note the measurement. This is done to prevent damage to the SRS system's contact reel.
Remove
- the front wheels.
- the front splash guard.
Detach the anti-roll bar links from the anti-roll bar.
Note! Clean and spray the exposed threads with rustproofing agent before beginning removal.
Remove (on both sides)
- the track rod end from the control arm. Use puller 999 5259 SEPARATOR 999 5259 Separator.
- the brake pipe bracket from the mounting in the wheel housing.
- the ABS sensor cable from the spring strut.
- the ABS sensor. Hang up the sensor.
- the screw holding the drive shaft to the hub.
- the nut of the ball joint/link arm.
Note! Counterhold using Torx 40 so that the ball joint's gaiter does not turn when the nut is removed.
Place a receptacle under the engine drain cock and drain the coolant.
Move the receptacle to the radiator's drain cock and drain any remaining coolant.
Close the nipples.
Remove
- the radiator hose from the radiator.
- the lower oil cooler hose from the transmission.
Note! Protect the openings against dirt.
Collect any oil or coolant spill.
Drain the fuel line. See Fuel system pressure release Fuel System Pressure Release.
Undo the fuel line's quick-release connector at the engine. See also Fuel system, quick-release connectors Description and Operation.
Note! Protect the openings against dirt.
Put the line to the side.
Detach the EVAP line at the quick-release connector.
Lowering the engine/transmission unit
Position a lifting table under the subframe with the table touching the subframe.
Note! make sure that the lifting table is centered under the subframe so that weight is distributed as evenly as possible.
Remove
- the screws of the subframe brackets.
- the screws of the subframe.
Lower the engine/transmission unit approx. 15 cm so that the drive shafts create a horizontal line between the hub and the transmission.
Note! Make sure that no hoses, wiring, or anything else catches when the engine/transmission unit is lowered.
Unhook the link arms from the ball joint pin.
Detach the drive shafts from the hub.
Note! Do not pull the drive shafts. They do not have axial locks.
Let the drive shafts rest against the link arms.
Continue lowering the engine/transmission unit.