Engine/Transmission, Removing

Engine/gearbox, removing

Special tools:
999 5666 Wrench 999 5666 Wrench
999 5722 Wrench 999 5722 Wrench

Note! Since the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.

Preparation





Remove:
- the battery negative cable. First read Battery, disconnecting Battery Disconnecting
- the cross stay between the suspension turrets
- the turbocharger control valve from the air cleaner (ACL)
- mass air flow (MAF) sensor connector
- the brake vacuum hose from the air cleaner (ACL)
- the air cleaner (ACL) assembly. Seal the openings in the intake pipe for the turbocharger (TC)
- the plastic charge air pipe above the engine. Seal the opening in the turbocharger (TC)
- the ground strip at the top/rear of the cylinder head.

Draining coolant




Position a container under the radiator drain cock.
Drain the coolant.

Warning! Avoid skin contact with the coolant.

Close the cock.

Depressurizing the fuel system
Depressurize the fuel system acc. to: Fuel system pressure release Fuel System Pressure Release.





Remove:
- the cover over the central electrical unit
- the connector for the engine wiring from the central electrical unit
- the positive lead for the starter motor from the terminal block
- the ground lead at the front frame member.

Removal of parts on transmission
Applies only to cars with automatic transmissions.

Remove:
- the screws for the gearbox cable bracket at the gearbox. Tie up the cable
- separate the gearbox wiring
- the oil cooler hoses for the gearbox. Seal the openings.




Applies only to cars with manual transmissions.
- Block the hose between the brake fluid reservoir and the clutch master cylinder
- Remove the retaining clip from the clutch pipe junction
- Disconnect the pipe from the junction.

Note! Seal the openings against impurities. Wipe up any spilled brake fluid.





Remove:
- connectors for temperature and pressure sensor in the charge-air cooler
- the rubber hose at the intake for the charge air cooler (CAC)
- the brake vacuum hose at the intake manifold
- the lower engine coolant hose from the engine
- the plastic pipe between the throttle body (TB) and the charge air cooler (CAC)
- the dip stick pipe. Separate the wiring from the front heated oxygen sensor (HO2S). Remove the wiring from the clips and clamps.

Removing components




Disconnect the connector for the level sensor in the expansion tank.

Remove:
- the hoses for the heater unit at the terminal in the bulkhead
- the bleed hose for the radiator at the expansion tank
- the ABS line and clips from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.





Remove:
- control module unit cover
- the control modules. Use mounting bracket 999 5722 Wrench 999 5722 Wrench
- the surround for the control module box.

Removing the connector with cable and cable protector




- Remove the red retaining clip from the connector using a screwdriver
- Disconnect the connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver
- Lift up the connector with the protection underneath and put it to one side
- Remove the ground cable on the right fender liner. Route the cable harness between the front plate and the AC pipe.

Disconnecting the connector





Remove:
- the right-hand headlamp by pulling up the two lock facings. Disconnect the wiring and put the wiring to one side
- the connector on the pressostat in the air conditioning (A/C) receiver drier
- the grey connector on the fan shroud. Remove the wiring from the clips and clamps on the fan shroud.

Exposing the air conditioning (A/C) compressor




- Remove the upper radiator hose
- Unhook the auxiliaries belt
- Disconnect the one-pin connector for the compressor magnetic clutch
- Remove the four screws holding the air conditioning (A/C) compressor to the engine. Tie up the compressor in the front cover plate.

Note! Handle the compressor carefully, make sure that there are no kinks in the AC-pipes.

Removing the lower steering shaft joint




- Set the front wheels so that they are straight
- Remove the soundproofing panel under the steering wheel. Fold back the floor carpet
- Bend up the outer section of the steering shaft boot
- Remove the retaining clip around the boot. Pull the boot up
- Turn the steering wheel to gain the best possible access to the steering shaft nut
- Remove the ignition key. Activate the steering wheel lock.

Caution! Do not move the steering wheel wince the contact reel in the SRS-system may be damaged.

Remove:
- the screw securing the mounting for the steering shaft in the joint
- the joint from the steering shaft by pressing the shaft upwards.

Removing components
Raise the car.

Remove:
- the left and right front wheels
- the splash guard under the engine.

Removing the front splash guards
- Remove the 6 screws.
- Lift up and slide the plate forward
- Remove the protective plate.

Note! There is a guide sleeve on the upper mounting for the plate, and this must be lifted slightly so that the panel can be slid forward.




Remove the track rod from the stub axle on the left and right-hand sides.
On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.





Remove on the left and right-hand sides:
- the link rod from the anti-roll bar
- the sound insulation cover for the drive shaft
- the nut holding the control arm to the ball joint
- the centre screw and the end of the drive shaft.

Separating the fuel line





Note! If an engine block heater is installed, mark the fuel lines.

Separate the quick-release connectors for the fuel pressure line and engine block heater (option).

Hint: Use tool 999 5666 Wrench 999 5666 Wrench.

Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.

Removing the three-way catalytic converter (TWC)
Remove the catalytic converter according to Three-way catalytic converter (TWC), replacing Service and Repair.

Removing the propeller shaft (all-wheel drive (AWD) only)
Remove the propeller shaft according to

Lowering the engine and gearbox




Use a post hoist with a lifting table and stud guides. Position the lifting table against the sub-frame.

Note! Make sure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

Removing the engine coolant heater (option)

Remove:
- the bumper cover on the left hand side. Use a weatherstrip tool
- the M8 nut at the top of the left-hand wing liner for the engine coolant heater
- the connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.





Remove:
- the screws for the sub-frame brackets
- screws in the sub-frame. Lower the engine/transmission unit approx. 15 cm so that the drive shafts create a horizontal line between hub and the transmission.

Caution! Make sure that no hoses, wiring or anything else catches in the engine and transmission unit when it is lowered.

- Unhook the control arms from the ball joint pinion
- Hold the constant velocity joint. Pull the drive shaft off the hub
- Let the drive shafts rest against the control arms
- Turn the engine block heater out of its position
- Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and gearbox unit.