Removal

Power Train

Removing the Power Train

WARNING: A large number of electrical leads, hoses, etc. are secured by means of cable ties. When these ties have been pulled tight, the excess length is cut off and may leave a sharp end at the fixing points. Beware of injuries like cuts and scratches on your hands caused by these sharp ends.





1. Lay out wing covers, remove the covers over the battery and intake manifold and remove the battery and battery tray. Open the expansion tank cap.
2. (aut.) Withdraw the breather hose, which sticks up under the main fuse box.
3. Disconnect the ground cable between the gearbox and the LH wheel housing. (aut.) Undo the cables to the gearbox. (man.) Unplug the reversing light connection for the gearbox. Raise the car and remove the lower engine cover.





4. Open the drain plug for the coolant.

WARNING: To prevent breakage of the airbag contact roller through twisting, the steering wheel should be fixed in place. Do this by taping it to the dashboard, for instance.





5. Turn the front wheels to the straight ahead position and secure the steering wheel in this position. Undo the steering column locking bolt and move the steering column upwards.





6. Disconnect the throttle cable and move it aside.
7. Disconnect the EVAP canister purge valve's vacuum hose from the intake manifold.
8. Disconnect the brake servo vacuum hose by pressing the red sleeve downwards and pulling the hose upwards.
9. Separate the fuel connections with Tool, fuel line separation 83 94 744 and plug them.

NOTE: If necessary, cut a groove in the rubber seal. Exercise care when doing this so that it can be re-used afterwards.





10. Disconnect the positive cable at the distribution terminal and the negative cable at the gearbox.





11. (man.) Disconnect the clutch slave cylinder's hose and plug the hose.
12. (man.) Engage 4th gear, remove the selector rod and engage 3rd gear.





13. (aut.) Disconnect the selector lever cable and bend it aside against the bulkhead partition.





14. Disconnect the upper radiator hose and remove the bypass valve's vacuum hose.
15. Remove the hose between the pipe connected to the throttle body and the charge air cooler and unplug the temperature sensor's connector.
16. Remove the bypass valve with intake manifold and plug same.
17. Unplug the connector for the radiator fan or fans. Remove the fan cowling retaining bolts, disconnect the upper radiator hose at the top and the pipe connected to the oil cooler (out.).
Carefully lift out the fan cowl.
18. Remove the grille.





19. Disconnect the hose between the turbocharger and charge air cooler and plug same.
20. Remove the mass air flow sensor with rubber gaiter and unplug its connector.





21. Disconnect the lower radiator hose from the water pump and disconnect the hose by the expansion tank as well as the hoses for the heat exchanger. For cars with ACC: Disconnect the vacuum hose from the bypass valve on the hose to the heat exchanger. Remove the radiator.
22. Remove the bracket with the connector for the engine wiring harness and the wiring harness mountings from the bulkhead. Unhook it and lay it on the engine.





23. Remove the wiper arms and the cover over the wiper assembly Use puller Puller 85 80 144.

NOTE: The plastic hooks go under the windscreen. The cover panel must first be pulled forwards.

24. Undo the control module connector's retaining nuts. Unplug the connector and place it on the engine.
25. Remove the hub nuts on both sides and raise the car.
26. Remove the front wheels.





27. Drive in Wedges 83 95 238 between the gearbox and subframe and between the oil sump and subframe.





28. Raise the car.
Remove the A/C compressor's retaining bolts.
29. Remove the retaining nuts and air hose from the air filter housing.
30. Lower the car to the floor.
31. Suspend the condenser cooler, charge air cooler and A/C compressor from the radiator member with Straps straps 83 95 212. The engine oil cooler is dismantled with the engine and fastened to the subframe with, for instance, cable ties.





32. Unplug the A/C compressor connector and undo the quick-release coupling on the vacuum hose connected to the wastegate.
33. Remove the right-hand engine mounting complete with yoke.





34. Relieve the pressure on the belt tensioner using a ratchet handle and lift off the multigroove belt.





35. Remove the left-hand engine mounting's retaining nuts.





36. Remove the power steering fluid reservoir with hoses and place it on the engine.
37. Pinch off the hose between the steering servo and reservoir.
38. Remove the sheet metal mounting on the pipe to the steering servo. Slightly loosen the steering servo hose so that it becomes moveable.
39. (aut.) Part the quick-couplings for the transmission oil cooler and plug. Use tool 83 95 261. Mark up the hoses so that they are not mixed up.
40. Raise the car higher.





41. Remove the three steering swivel joint retaining nuts on both sides.
42. Undo the nuts securing the anti-roll bar supports to the suspension strut.
43. Undo the two outer steering links. Use Puller ball jointed 96 696.
44. Carefully tap the drive shafts out of the hubs.
45. Remove the oil cooler and suspend it from the front of the engine frame.





46. Separate the exhaust pipe behind the catalytic converter and remove the temperature sensor.
47. Run Lifting trolleyed 83 94 739 with assembly fixture 83 95 196 under the car. Align the fixture with adjusting feet 83 95 170 under the subframe with the locating studs at front left and rear right.
48. Remove the 10 subframe and supporting plate retaining bolts.
From chassis number W3050999, the inner sleeve in the subframe bushings has been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer.

WARNING: The spacer washer must not be fitted together with a bushing with 38 mm inner sleeve.

49. Lower the lifting trolley approx. 25 cm and thus also the subframe and power train. Make sure that the swivel joints release and lift out the drive shafts. Unhook the hose for the engine oil cooler from its bracket on the subframe.
50. Pull the trolley as far back as possible to provide room for the A/C compressor and lower carefully.
51. Then lower the power train complete with subframe, steering gear and front exhaust pipe.