Removing
Removing
Preparations
Note! Avoid skin contact with the oil.
The method description applies to all engine options. The figures primarily shown the turbocharged engine (B5234T) in early and late designs. The figures show the right-hand drive design only when difference to the working method apply.
Set the steering wheel position.
Remove the lever for steering wheel adjustment.
Push the steering wheel to the bottom position and angle upward as far as possible. Lock the steering wheel with the lever.
Place the gear-shift selector in the N-position.
Remove:
- The battery
- The battery shelf
- The air cleaner (ACL) housing assembly with the intake pipe.
Remove the timer valve from the air cleaner (ACL) housing (Turbocharged engines only)
Only cars with turbocharged engines, early design
Remove the clamp from the charge air pipe. Remove the hose from the pipe.
Remove:
- The intake manifold (from the air filter) to the turbocharger
- The cover over the control bobbin
Remove:
- The pipe to the throttle housing. Hold the pipe to the side with a strap.
- The upper oil cooler hose to the engine's cooler.
Seal all openings on oil connections with plastic plugs.
See item Removing the transmissions cable and connector.
Only cars with turbocharged engines, late design
Remove:
- The cover over the control bobbin. Unhooked the throttle cable from the control bobbin and bracket.
- Charge air pipe between the turbocharger and the cooler. Remove the bracket by the torque arm's stay. Refit the nut on the stay.
- The inlet manifold (from the air filter) to the turbocharger.
Remove:
- Charge air pipe to the throttle housing.
- The upper oil cooler hose to the engine's cooler.
Seal all openings on oil connections with plastic plugs.
Hold the lower pipe to the intercooler to the side with a strap.
Removing the transmissions cable and connector
Remove:
- The transmission cable from the transmission.
- Connector from the gearbox. Note the rubber seal.
- The clamps to the cable harness and ground cable on the gearbox alternatively sub-frame.
Note! The fastening points can vary depending on the model year.
Earlier version:
- The gearbox's air vent hose from the clamp.
Later version:
- Remove/unhooked the cable conduit from the gearbox
- Removed the heated oxygen sensor's connector from the bracket on the gearbox.
Remove the hoses to the gearbox's oil cooler.
The supply hose by the cooler's upper snap-on coupling and return hose by the gearbox.
Remove the oil dipstick pipe.
Seal all openings with plastic plugs.
Vehicles with EGR: Remove the hoses from the converter.
Remove the nut on the rear engine pad.
Remove:
- The screws between the gearbox-engine and gearbox-starter motor (x5).
Lift the cooler's expansion tank from the bracket and let it hang free.
Remove the ground braid from the firewall.
Remove the screw to the torque stay-torque arm by the engine.
Install the lifting fork 999 5534 LIFTING FORK 999 5534 Lifting Fork for the torque stay/engine.
Installing the lifting device
Install:
- The support 999 5033 SUPPORT 999 5033 Support on the fender edges.
- Lifting bar 999 5006 LIFTING BAR 999 5006 Lifting Bar on the support. Place the bar straight above the eye on the lifting yoke.
- Lifting hook 999 5460 Lifting hook 999 5460 Lifting Hook.
Note! When lifting hooks in the early design (A) are used, the hook must be 999 5186 HOOK 999 5186 Hook connected between the lifting fork and the lifting hook. Lifting hook, late design (B).
Tightened the hook approximately 5 mm so that the engine pants off-loaded slightly.
- Measure and note the measurement between the lifting bar and the spark plug cap.
Remove:
- The front wheels
- The ABS sensor from the wheel spindle (left-hand side).
Note! Do not disconnect the connector.
Remove:
The brackets to the brake pipes and ABS cables (both sides). Unhook the brackets and let them hang freely.
Remove:
- The front plastic nuts for the wheel arch liners (both sides) and the two Torx screws on the left-hand side (early design).
- Left-hand drive shaft nut. Remove the nut lock. (Only applies to early design.) Position the counterhold 999 5461 COUNTERHOLD 999 5461 Counterhold (4 wheel studs) or 999 5540 COUNTERHOLD 999 5540 Counterhold (5 wheel studs). Remove the nut.
Remove the drive shaft end in the hub.
Knock the drive shaft end into the hub approximately 10-15 mm. Use a plastic or copper hammer!
Remove:
- Both screws on the front protective casing. Press the casing forward so that the guide on the rear edge releases. Loosen the front edge of the casing and remove.
- Casing under the engine (Early design).
Remove the control arm/ball joint from the wheel spindle (both sides)
Install the protective sleeves 999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket on the ball joints (both sides).
Loosen and unhook the linkages from the anti-roll bar.
Remove:
- Remove the cable conduit mounting screw on the sub-frame and unhook the pipe from the frame.
Loosen the carbon filter holder with hoses from the sub-frame.
Cut the cable tie on the hoses and hang up the holder on the body.
Loosen the clamp on the exhaust pipe behind the catalytic converter.
Draining oil
Remove:
- The screws on the oil pipe's brackets.
- The two screws for the torque stay mounting's bracket on the gearbox.
Drain the transmission oil.
Note! Only if the gearbox must be replaced or if the oil is to be changed. Drain plug torque: 40 Nm.
Warning! The oil can be very hot.
Right-hand drive cars only
Remove the collision protection system above the steering gear (2 screws).
Loosen the right drive shaft
Remove the bearing cap. Pull out the inner section of the drive shaft and fold out the spring strut at the same time.
Note! Take care not to damage the seal in the transmission.
Install the seal plug 999 5488 PLUGS 999 5488 Plugs in the gearbox.
Let the drive shaft rest on the sub/frame. Secure the drive shaft end with tape by the pipe bend.
Right-hand drive cars only:
Let the drive shaft end rest temporarily on the oil pipe.
Remove the screw, front engine pad/sub-frame
Loosen the screw for the engine pad/steering gear about one turn.
Remove the securing nuts for the steering gear on the sub-frame (x5).
Right-hand drive cars only:
Remove the nut (A) for the collision protection system /sub-frame.
Remove the sub-frame from the car.
Place the jack as a support 999 5972 FIXTURE 999 5972 Fixture under the left-hand side of the sub-frame, applied lightly.
Remove the screws for the sub-frame support brackets on the body (both sides).
Unscrew the screws between the frame and body (right-hand side) about 15 mm.
Remove the screws on the left-hand side.
Right-hand drive cars only
Lower the sub-frame approximately 100 mm.
Make sure that the 5 steering gear screws and the collision protection system screws release from the frame.
Remove the screws for the anti-roll bar's bearing cap (left-hand side). Loosen the screws on the right-hand side so that only a few threads remain.
Tie up the anti-roll bar tot he steering gear as illustrated.
Lowering the sub-frame
Note! Check that the steering gear screws are free of the sub-frame. Ensure that the control arm is free of the right drive shaft boot.
Remove the mobile jack.
Let the frame hang freely from the screws on the right-hand side.
Right-hand drive cars only:
Tape the rear edge of the drive shaft end to the oil pipe.
Remove the earth cable from the gearbox.
Suspend the steering gear with the hook 999 5045 COMPRESSION HOOK 999 5045 Compression Hook in the hole on the frame member's flange.
The figure to the right shows the right-hand drive vehicle.
Remove the screw to the steering gear, engine pad and the nut on top engine pad. Remove the engine pad.
Note! Ensure that the steering gear hangs securely on the hook so that the lower steering shaft does not slide out of the steering column.
Remove:
- The clamps on the heated oxygen sensor cable from the cover.
- The connector and cable to the vehicle speed sensor.
Remove:
- The cover at the rear engine mounting.
- The rear engine mounting from the gearbox
Removing the left drive shaft
Turn and fold out the spring strut. Knock the end of the drive shaft using a plastic or copper hammer and pull out the drive shaft from the hub. Use the jimmy tool 999 5462 Jimmy tool 999 5462 Jimmy Tool between the gearbox and the inside of the drive shaft.
Note! Take care not to damage the sealing ring in the gearbox or the boot on the drive shaft.
Install the sealing plug 999 5488 PLUGS 999 5488 Plugs in the gearbox. Clean any metal adhesive from the spline joint (hub- drive shaft).
Lowering the engine and the transmission
Lower using the lifting hook until the distance between the lifting bar and the spark plug cap approximately 320 mm .
Note! If the engine is lowered too much, the exhaust pipe can press the steering gear down.
Note! Ensure that cables and hoses are not pinched or stretched and that the engine dipstick is free from the fan.
Fit universal tool 999 5972 FIXTURE 999 5972 Fixture and transmission fixture 999 5463 FIXTURE 999 5463 Fixture on the mobile jack.
Install the gearbox fixture on the gearbox with the torque stay mounting's screws.
At the same time align the support plate (marked 999 5463-1) on the fixture. Lightly apply the jack.
Remove the 6 screws for the torque converter.
Use a socket Torx TX50 (earlier models TX40).
Remove the lower plastic nut and fold out the right-hand wheel arch liner. Turn the crankshaft using a socket wrench.
Remove the 7 screws between the engine and gearbox.
Remove the transmission
Ensure that the torque converter follows the transmission and that it does not slide off of the stator shaft. The use of the hole in the torque converter cover to press on the torque converter. See the figure to the left.
Note! Do not pry toward the carrier plate rim for the flywheel sensor.