Engine/Transmission, Removing
Engine/transmission, removing
Special tools:
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5722 Wrench 999 5722 Wrench
Note! Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information is always correct.
Preparation
Remove
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
- the cross stay between the suspension turrets
- the air cleaner (ACL) assembly. Seal the opening in the plastic pipe for the turbocharger (TC)
- the plastic charge air pipe above the engine. Seal the openings
- both the ground strips at the top of the cylinder head.
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.
Remove
- control module unit cover
- the control modules. Use tool 999 5722 Wrench 999 5722 Wrench. See also Engine control module (ECM), replacing Service and Repair.
Separate the control module box. Disconnect the engine wiring. Also see Central electrical unit, engine compartment, replacing Central Electrical Unit Engine Compartment.
Remove the ground terminal for the engine wiring at the right wheel arch.
Removing the engine cooling fan (FC)
Remove
- the brake vacuum hose from the ejector valve
- The canister purge (CP) valve from the mounting on the fan shroud. Disconnect the connector.
Expose the wiring and the breather tube for the radiator.
Disconnect the connectors for the engine cooling fan (FC).
Remove
- the screws securing the fan shroud to the front panel
- the dip stick
- the upper oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.
Lift up and remove the engine cooling fan (FC).
Remove
- the connectors for the pressure sensor and temperature sensor in the plastic charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
- the rubber hose at the intake for the charge air cooler (CAC)
- the brake vacuum hose at the intake manifold
- the plastic pipe between the throttle body (TB) and the charge air cooler (CAC)
- the lower oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.
Install radiator protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
Removing the transmission cable
Automatic transmissions: Remove the screws for the transmission cable bracket at the transmission.
Manual transmissions: Separate the clutch cable and remove the transmission cables.
Tie up the cable(s) to the central electrical unit.
Draining the fuel line
Drain the fuel line. See Fuel system pressure release Service and Repair. See also: Fuel system, quick-release connectors Description and Operation.
Remove the cover from the expansion tank.
Removing components
Raise the car.
Remove
- the left and right front wheels
- the splash guard under the radiator
- the splash guard under the engine.
Draining coolant
Position a container under the radiator drain cock.
Drain the coolant.
Warning! Avoid skin contact with the coolant.
Close the cock.
Cars with engine block heaters (option)
Drill out the first three blind rivets at the right mounting for the fender lining to the fender edge, seen from the front edge and upwards.
Bend the fender liner out of the way.
Disconnect the connector from the engine block heater.
Preparations for removal of the drive shafts
Remove on the left and right-hand sides
- the tie rod from the wheel spindle
- the link rod from the anti-roll bar
- the screw that holds the brake pipe bracket to the bodywork
- the nut holding the control arm to the ball joint
- the center screw from the end of the drive shaft.
Separating the fuel line
Note! If an engine block heater is installed, mark the position of the fuel lines.
Separate the quick-release connectors for the fuel pressure line and engine block heater (option). See also: Fuel system, quick-release connectors Description and Operation.
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.
Separating the front exhaust pipe
Remove the screw from the wiring clamp that holds the wiring for the heated oxygen sensor (HO2S) at the right side of the steering gear.
Remove the wiring from the clips at the power steering line on the steering gear.
Remove
- the screw for the wiring clamp at the bracket at the rear edge of the sub-frame
- the lower screw that holds the heat deflector plate over the turbocharger (TC)
- the three nuts that hold the front exhaust pipe to the turbocharger (TC).
Tie up the front exhaust pipe at the right suspension turret (cars without All-wheel drive (AWD)).
Removing the air conditioning aggregate
Disconnect the connector from the pressostat in the air conditioning (A/C) receiver drier.
Slacken off the lower right screw for the cooling unit.
Pull the cooling unit down. Carefully pull the wiring for the pressostat through the cavity at the mounting for the cooling unit.
Release the lower ventilation pipe for the control module box from the sub-frame.
Exposing the air conditioning (A/C) compressor
Remove the upper radiator hose.
Remove 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 to make sure that there is no bending of the AC-pipes.
Removing components
Expose the wiring for the front heated oxygen sensor (HO2S).
Disconnect the connector for the level sensor in the expansion tank.
Remove
- the heat deflector plate above the turbocharger (TC)
- the hoses for the heater unit at the terminal in the firewall
- the bleed hose for the radiator at the expansion tank
- the ABS line and clips and the power steering hose.
Lift up the power steering fluid reservoir and the expansion tank. Place them on top of engine.
Separating the steering shaft
Remove the ignition key.
Remove the screw from the joint between the steering gear and the steering shaft.
On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.
Press up the joint from the steering gear.
Caution! The steering shaft must not be turned. The contact reel in the SRS system could be damaged.
Removing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
Remove
- the nuts where the exhaust pipe divides downstream of the three-way catalytic converter (TWC)
- the screws securing the SIPS member to the bodywork.
Remove the brake pipe from the holders on the SIPS member.
Lift off the front exhaust pipe from the turbocharger (TC) and the rear system.
Lower and pull back the three-way catalytic converter (TWC) with the SIPS member.
Note! The routing of the heated oxygen sensor's cable harness over brake pipe.
Removing the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only)
remove the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only). See Pinion seal bevel gear, replacing Pinion Seal Bevel Gear, Replacing.
Lowering the engine and transmission
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.
Remove
- the sub-frame brackets screws
- the screws for the sub-frame.
Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.
Caution! Make sure that no hoses, wiring or anything else catches when the engine/transmission unit 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 transmission unit.