Procedures
Engine, lifting out/in
Special tools:
999 2810 LIFTING YOKE 999 2810 Lifting Yoke
999 5185 HOOK 999 5185 Hook
999 5428 LIFTING YOKE 999 5428 Lifting Yoke
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5464 LIFTING EYE 999 5464 Lifting Eye
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5488 PLUGS 999 5488 Plugs
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5722 Wrench 999 5722 Wrench
Lifting out the engine and transmission
Note! As 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 negative battery cable. First read Battery, disconnecting Battery Disconnecting.
- the expansion tank cap.
- Mark up and unplug the connectors for the heated oxygen sensors.
- Loosen the holder for the heated oxygen sensor wiring at the transmission.
Drain the fuel system. See: Fuel system pressure release Fuel System Pressure Release.
Part the fuel line and the EVAP-line's quick-coupling at the right rear attachment of the sub-frame.
Note! Protect the openings from dirt. Place the wiring to one side. Make sure that all cleanliness conditions for working with the fuel injection system are followed.
Position a container at the drain nipples to collect the coolant.
Open the nipples on the engine and the radiator.
Thread hoses onto the relevant nipple to collect the coolant.
Loosen the lower charge-air pipe from the charge-air cooler's lower sleeve.
Close the nipples.
Remove
- the left front wheel
- tie rod end from the spindle.
- the screw of the ball joint/wheel spindle.
Detach the link arm/ball joint from the wheel spindle.
Pull down the link arm to release the ball joint.
Install the protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint.
If the ball joint is difficult to move in the wheel spindle, tap a screwdriver into the wheel spindle groove.
- the screw for the bracket for the ABS-cable and brake pipe/hose.
- left drive shaft.
Pry tools 999 5462 Jimmy tool 999 5462 Jimmy Tool must be used to avoid damaging the lock ring.
- the right front wheel.
- tie rod end from the spindle.
- the screw of the ball joint/wheel spindle.
Note! If the ball joint is difficult to move in the wheel spindle, tap a screwdriver into the wheel spindle groove.
Detach the link arm/ball joint from the wheel spindle.
Pull down the link arm to release the ball joint.
Install the protective sleeve 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joint.
If the ball joint is difficult to move in the wheel spindle, tap a screwdriver into the wheel spindle groove.
- the track rod end from the right wheel spindle.
- the right drive shaft and intermediate bearing cap.
Carefully position the drive shaft on the power steering pipes.
- both screws of the right engine mounting.
First bend the right fender liner slightly so that it is out of the way.
- lower torque rod's through-bolt and nut at the transmission.
Note! Install sealing plugs 999 5488 PLUGS 999 5488 Plugs in the holes where the drive shafts were positioned.
- the SIPS-member.
- the lower nut of the front exhaust pipe.
- lift down exhaust pipe.
- the speedometer connector.
- the lower screws of the front and rear engine mountings.
Lower the car to a suitable work height.
Lower the car to suitable working height and remove:
- the battery.
- the battery shelf.
- the connector from the mass air flow sensor (HFM-unit).
- the intake hose for the turbocharger from the air cleaner cover.
- the intake hose between the air cleaner housing and the front panel.
- the solenoid valves from the air cleaner housing.
Place them over the engine.
- the air cleaner assembly.
- the upper torque rod.
- the braided ground cable between the engine and the cowl panel.
- the heat deflector plates at the turbocharger.
- the upper nuts of the front exhaust pipe.
- the heater hoses from the cowl panel
- the brake vacuum hose from the intake manifold.
Place it to one side.
Mark and disconnect the heated oxygen sensor connectors.
Undo the retainer for the heated oxygen sensor wiring at the transmission.
- the air duct to the control module.
- the connectors, relays and EVAP canister purge valve from the fan shroud.
Place the wiring to one side.
- fan shroud and the relay holder's attachment.
Lift up the relay holder and remove the upper hose between the charge-air cooler and the intake pipe.
Seal the openings.
Press back the charge-air pipe and lift up the cooling fan with the fan shroud.
Note! First loosen the attaching screw on the clamp located on the throttle body (ETM-unit) so that the charge-air pipe is not bent.
Install radiator protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
- the charge-air hose from the lower connection of the charge-air cooler.
- the lower coolant hose from the radiator.
- cover over the wiring to the starter motor.
- the ground cable on the transmission.
Note!
Applies to cars with manual transmission:
- Disconnect the clutch cable.
Note! Protect the clutch cable's free connections in a suitable way with drying paper:
- Make sure that all cleanliness conditions for working with the hydraulic system are followed.
Remove:
- the air cleaner housing bracket.
Applies to cars with manual transmission:
- Remove the gear selector cables from their mountings on the transmission.
Mark the cables.
- Remove the rubber-suspended section of the gear selector mounting.
Applies to cars with automatic gearbox:
- Detach the connector and detach the gear selector cable from the transmission.
Mark up the wire.
- Loosen the two oil cooler hoses from the cooler using, e.g., lock ring pliers.
Remove
- the upper radiator hose from the thermostat housing.
- the expansion tank.
- the auxiliaries belt
- the 3 screws holding the power steering pump.
Loosen through the holes in the power steering pump's drive gear.
Disconnect the temperature sensor cable from the bracket on the power steering pump.
Note! Leave the power steering pump in place for now.
Unplug the connector of the AC compressor's electromagnetic clutch.
Remove the four screws retaining the air conditioning (A/C) compressor in the engine.
Start with the lowest screws.
Note! Take care that the pipe does not break or crack when the upper screws are loosened.
Remove the AC-compressor and hang it up on the front cover plate.
Remove the cover from the control module box.
Note! Do not touch the connector pins on the control module with your fingers. Components in the control module can be damaged by static electricity.
Insert tool 999 5722 Wrench 999 5722 Wrench around the control module.
Move the tool's upper part to stop.
Pull up the tool.
Carefully pull up the control module.
Remove the intermediate section of the control module box.
Pry out the connector plate from the lower section of the control module box.
Disconnect the engine and transmission wiring connectors.
Place the engine and transmission wiring on top of the engine.
Lifting out the engine and transmission
Lift up the power steering pump and put it to one side.
Use lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke.
Fit hook 999 5185 HOOK 999 5185 Hook between the engine's lifting lugs at the auxiliaries bracket and the upper torque rod bracket.
Fit lifting lug 999 5464 LIFTING EYE 999 5464 Lifting Eye in the exhaust manifold.
Fit mounting bracket 999 5428 LIFTING YOKE 999 5428 Lifting Yoke to the hooks and lifting eye.
Lift out the engine while observing the following:
Remove the front engine pad when lifting.
Adjust the lift angle throughout the lift.
A relatively large angle is required.
Note! Check carefully that the drivetrain goes free of the bodywork and any optional equipment, and also make sure that no engine or transmission wiring catches during the lift.
Reinstalling the engine and transmission
Note! For tightening torques, see: Tightening torque, B5234T9 Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Reinstalling the engine and transmission
Use lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke , mounting bracket 999 5428 LIFTING YOKE 999 5428 Lifting Yoke , lifting eye 999 5464 LIFTING EYE 999 5464 Lifting Eye and 2 hooks 999 5185 HOOK 999 5185 Hook.
Align the lifting yoke so that the weight of the engine is evenly distributed.
Adjust the hoist angle throughout the lift.
Note! Check that the drivetrain goes clear of the bodywork and any optional equipment.
Make sure that the wiring does not catch during the lift.
Tighten the nut of the front engine mounting.
Finishing
Install the engine and transmission wiring.
Plug in the engine and transmission wiring connectors to the connector plate.
Press the connector plate into place in the lower section of the control module box.
Install the intermediate section. Align the ventilation pipe at the rear edge of the control module box.
Screw the control module box into place in the fender liner.
Press the control modules down carefully.
Lock into place using mounting bracket 999 5722 Wrench 999 5722 Wrench.
Press the cover into place.
Install
- the AC-compressor
Tighten with 25 Nm .
Plug in the connector of the AC compressor's electromagnetic clutch.
- the engine and transmission wiring in the mountings on the subframe.
- power steering pump's 3 screws.
Tighten with 25 Nm .
Plug in the connector of the water temperature sensor.
- the expansion tank and coolant hoses
- the upper radiator hose
- the auxiliaries belt
- the air cleaner housing bracket.
Applies to cars with manual transmissions
- cable for the reverse light switch.
- the rubber-suspended mounting for the gear selector cables.
- the gear selector cables in the mountings on the transmission.
Note! Colour marking bracket/wire.
Applies to cars with automatic transmissions
- Plug in the connector of the transmission.
- Attach the gear selector cable using the previous marking.
- Install the transmission's two oil cooler hoses and the negative cable to the transmission.
Note! Applies to cars with manual transmission: Connect the clutch cable. Install a new quick-coupling on the clutch cable's connection.
Install:
- the ground cable on the transmission.
- the wiring to and the cover over the starter motor.
- the lower coolant hose from the radiator.
- the charge air hose to the lower connection of the charge air cooler.
Remove:
- protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection from the radiator.
Install:
- the engine cooling fan assembly with shroud.
Plug in the connector and clamp the wiring.
- upper charge-air pipe between charge-air cooler and turbocharger.
Remove the seals.
- the fresh air intake.
- upper fan shroud.
Tighten the fan shroud to the radiator.
Make sure that the clips are securely in place.
- the canister purge valve in its bracket and connect the EVAP canister vacuum hose.
- the air duct for cooling the control module box.
- both relays on the upper fan shroud and plug in the connectors.
Clamp the wiring.
- Tighten the clamp by the throttle body(ETM-unit).
Plug in the heated oxygen sensors' connectors as marked.
- the holder for the heated oxygen sensor wiring on the transmission.
- the brake vacuum hose on the intake manifold.
- the heater hoses on the cowl panel.
- the upper nuts of the front exhaust pipe.
Do not tighten yet .
- the ground braid between the engine and the firewall.
- the upper torque rod.
Tighten on the engine with 35 Nm + 90 ° on engine and with 35 Nm + 60° at the firewall.
- the air cleaner assembly.
- the solenoid valves at the air cleaner cover.
- the intake hose between the air cleaner housing and the front panel.
- the intake hoses for the turbocharger at the air cleaner cover.
Plug in the connector for the mass air flow sensor (HFM-unit).
- the battery shelf.
- the battery: Battery, disconnecting Battery Disconnecting.
Lift up the car and plug in the speedometer's connector.
- the front and rear screws for the engine mounts.
Tighten to 50 Nm .
- the torque rod's through-bolt in the transmission.
Use a new screw and nut.
Tighten to 35 Nm and angle tighten 90° .
- both screws of the right engine mounting.
First bend the right fender liner slightly so that it is out of the way.
- the right drive shaft and support bearing.
- left drive shaft.
Note! Press in the drive shaft by hand, since the lock ring is easily damaged.
- the screw of the bracket for the ABS line/brake pipe.
Remove the cover of the ball joint and link arm retainer.
Note! Do not damage the ball joint gaiter.
- ball joint/link arm on the wheel spindle.
Make sure that the ball-joint's groove fits against the screw holes in the wheel spindle.
Use a new lock nut.
Tighten to 50 Nm .
Install:
- the front wheels.
Lower the car.
Torque-tighten the exhaust pipe's three nuts and check that the faces are parallel.
Tighten with 25 Nm .
Install the heat deflector plate with the bracket for the turbocharger.
Connect the battery's minus cable. Battery, disconnecting Battery Disconnecting.
Top up the coolant.
Coolant volume approx.: 7 liters .
Fill engine oil.
Oil volume, including filter: 5.8 liters .
Check the function
- Connect a VIDA station.
- Start the engine and run it until the thermostat opens.
- Check with VIDA car communication that no diagnostic trouble codes are stored.
- Check sealing.
- Check and if necessary adjust the oil and coolant levels
Automatic transmissions: Check the transmission fluid level.
Wipe clean.
Wipe the engine compartment clean.
Wipe clean steering wheel and gear lever.