Removing and Installing (Engine Installed)
Rear Spoiler, Exploded View:
REMOVAL
1. Disconnect battery.
NOTE: Before disconnecting the battery, it is recommended to read out the fault memory of the DME control unit using System Tester 9288. Thus any irregularities can be taken into account during the subsequent assembly jobs, if required.
2. Remove rear spoiler
Loosen the following items:
1 - Screen
2 - Nut (4 pcs.)
3 - Sheetmetal screw
4 - Light assembly
5 - Pan head screw (3 pcs.)
6 - Bracket
7 - Closing panel
8 - Oval-head sheetmetal screw (B 4.8 x 18)
Washer 5x26x 1
9 - Combination screw (6 pcs.)
10 - Rear spoiler
11 - Seal
12 - Hexagon nut (9 pcs.)
13 - Heat shield of closing panel
14 - Sheetmetal screw (4 pcs.)
15 - Washer 5 x 26 x 1(4 pcs.)
16 - Pan head screw (2 pcs.)
17 - Washer (2 pcs.) A 13
18 - Bumper support
3. Remove engine underside tray.
4. Remove sealing frame and charge air cooler. While doing so, do not drop the square fastening nuts of the lower charge air cooler bracket.
CAUTION: Plug-seal pressure hoses immediately against foreign substances.
5. Unplug, unlock and separate oxygen sensor connections.
O2 Connectors:
1 - Oxygen sensor ahead of cat. conv.
2 - Oxygen sensor behind cat. conv.
(cylinder bank 1 - 3)
O2 Connectors:
1 - Oxygen sensor ahead of cat. conv.
2 - Oxygen sensor behind cat. conv.
(cylinder bank 4 - 6)
6. Extract rubber sleeves from engine paneling and pull wires down. Detach wire clamps from bracket.
NOTE: The double sleeve of the right-hand oxygen sensors is hard to access. Remove A/C compressor from bracket and put it aside.
7. Remove muffler.
Converter Cover:
8. Remove cover. Detach catalytic converter from turbocharger and remove it.
9. Drain engine oil at turbocharger/oil tray.
10. Loosen oil return line between turbocharger/oil tray and bracket.
11. Remove heating tube.
12. Use car-jack to support engine.
CAUTION: Secure lifting platform.
Engine Carrier:
13. Loosen engine carrier.
14. Detach and remove NC compressor bracket.
Turbo Oil Pump:
Exploded View
Key to View
INSTALLATION
1. Do not mix up gearwheels when cleaning or sealing oil pump.
2. Rework bracket, if required. Inadequate machining of the A/C compressor bracket may make it impossible to remove or install the V-belt of the fan wheel in the right-hand area of the A/C compressor bracket. For this reason, the bracket should be checked and reworked while removed.
3. Remove V-belts of alternator and fan wheel.
Bracket:
4. Use a flexible file blade (length approx. 350 mm) to remove part of the cast profile until the V-belt of the fan wheel can easily be removed and installed between the lower belt pulley and the bracket.
WARNING: Wear protective gloves during filing!
Bracket:
As of engine number 61T02452 the bracket has been reworked by the manufacturer.
5. Fit bracket.
Oil Return Line:
6. Before fitting bracket to crankcase, fit connecting piece (oil return line) into bracket. Lubricate 0 rings.
Establishing Torx Connection:
7. When fitting bracket to crankcase, use a screw driver to establish Torx connection between oil pump drive shaft and driver in intermediate shaft; do not apply force, but press cautiously with hand.
8. Tighten bracket.
9. Tighten screw cap (no. 12).
10. Install all exhaust and body pieces in reverse order of removal.