Replacement of Control System Cable Harness With Oil Temperature Sensor
Replacement of control system cable harness with oil temperature sensorSpecial tools: 998 5972, 999 5185, 999 5460, 999 5477, 999 5562, 999 5563, 999 5716, 999 5572
Note: Since the same illustrations are used for different model years and/or model variants, certain discrepancies may occur. The most important information will always correspond to the model concerned, however.
Removing engine compartment parts
Sealing Ring, Gear Shift Linkage Rod, Replacing
Detach the gear change cable from the lever on the transmission and the two cable bracket screws.
Move the cable aside.
Unplug the connector from the transmission.
Undo the cable tie holding the cable harness leads together.
Separate the connector halves.
Dismantling the large connector
Remove the sockets for the leads.
Remove the oil temperature sensor and the parts of the solenoids in the connector.
Removing the lever on the control shaft
Remove:
- the lever on the control shaft
- the screw for the gear selector position sensor/cable harness.
Bend out the lug on the cable harness retainer.
Fitting lifting yokes and hooks
Position lifting yoke 999 5716 directly over the engine's lifting eye. Arrange the lifting yoke brackets as shown in the illustration. Attach hooks 999 5460 and 999 5185 to the lifting eye at the rear of the engine. Take up the slack in the hooks and tension them to relieve the pressure on the engine pads.
Raising the car
Note: Position the front lifting arms so that they do not block the subframe's support plates.
Remove:
- LH front wheel
- front protective cover.
Removing the screws securing the cable conduit and ground lead's bracket on the subframe
Remove the carbon filter canister from the subframe.
Unhook the hoses from their brackets.
Removing the link arm's ball joint from the stub axle on the left-hand side.
Use compressed air to blow the area round the ball joint clean.
Spray rust remover generously on the ball joint and the nut and bolt securing it.
Preparations for removing the ball joint
If the bolt is rusted in, slacken the nut a few turns.
Then tap the bolt loose.
Remove the nut and bolt.
Spray rust remover on the ball joint once again.
Note: Do not drive a chisel, screwdriver or drift between the "ears" on the stub axle.
Removing the ball joint from the stub axle
Tap the ball joint free. Use a socket between hammer and ball joint.
Note: The inside diameter of the socket must be larger than the outside diameter of the cover to avoid damaging the cover.
Spray rust remover on the ball joint once again.
Removing the ball joint/link arm from the stub axle
Move the ball joint up and down by hand (or use a crowbar) until it comes loose from the stub axle.
Fit protective sleeve 999 5562 on the ball joint.
Fit retainer 999 5563 on the link arm when the ball joint has been removed.
Remove the nut from the anti-roll bar link on the LH side. Unhook the link from the anti-roll bar.
Removing components from the subframe
Remove:
- the steering gear nuts the screws securing the oil brackets
- the screws securing the oil pipe brackets
- the bolt from the front engine pad/subframe
- the torque rod attachment bolts in the transmission
Removing on RHD cars only
Remove:
- the collision guard over the steering gear
- the nut for the collision guard/subframe.
Preparations for lowering the subframe
Detach the subframe from the car.
Position engine lift 998 5972 under the LH side of the subframe. Abut it lightly against the subframe. Remove the bolts from the subframe support plate on both sides.
Undo the subframe bolts on the RH side. Unscrew the bolts until at least five turns still hold them in place.
RHD cars only: Lower the subframe about 100 mm.
Make sure that the five steering gear bolts and the collision guard bolt are unscrewed from the subframe.
Remove the anti-roll bar's clamp bolts (LH side).
Undo the bolts on the RH side until only a few turns still hold them in place. Tie the anti-roll bar to the steering gear as shown in the illustration.
Lowering the subframe
Note: Make sure that the steering gear and collision guard come away from the subframe.
Lower the subframe to expose the control system casing.
Drain the oil from the transmission.
Place a receptacle under the transmission.
Drain the oil. Measure the amount of oil and make a note of it. Then tighten the plug to 40 Nm.
Remove the clamp for the cable harness on the control system casing. Detach the ground cable from the transmission. Secure the cable harness and ground cable.
Detach the oil cooler's return line from the control system casing.
Detach the oil cooler's pipe/hose from the transmission. Move the pipe aside.
Seal the hole in the transmission with a plastic plug.
Bend the oil temperature sensor lead aside.
Removing the control system casing
Remove the screws securing the control system casing (Torx TX40).
Clean the threads, removing all traces of sealant. Use an M8 x 1.25 thread tap.
Remove the casing. Use gasket wedge 999 5477. Carefully tap it in between casing and transmission, making sure that the casing's sealing flange is not skewed. Remove all gasket remnants from casing and transmission.
Note: Exercise care so that no gasket remnants fall into the transmission. Thoroughly clean the casing.
Removing the cable harness
Remove:
- the solenoid valve connectors
- the screws securing the retainer for the oil temperature sensor. Remove the sensor from the control system
- the cable harness from the retainer on the control system.
Remove the cable harness.
Connect the cable harness
Plug the cable harness connectors into the solenoids.
Lubricate the O-rings for the cable harness lead through and the oil temperature sensor with ATF oil.
Fit the cable harness. Plug the connectors into the solenoids.
Fit the oil temperature sensor with retainer and screw. Tighten to 10 Nm.
Fit the cable harness to the retainer. Check that the cable harness is correctly positioned.
Assembling the control system
Sealing the casing
Check that the casing's mating surface is clean and flat.
Wipe off the cleaned sealing surfaces on casing and transmission with methylated spirits.
Note: Take care to ensure that no impurities or foreign objects get into the transmission.
Apply a bead of sealant about 3 mm thick on the casing. Part number 1161409-6. Also apply sealant round the screw holes.
Fitting the control system casing
Fit the control system casing on the transmission.
Tighten the bolts alternately to 12 Nm. Torx TX 40.
Run the lead to the oil temperature sensor.
Fit:
- the oil pipe to the transmission using a new O-ring
- the return line to the control system casing
- the cable harness to the retainer on the casing
- the ground cable to the transmission.
Fitting the subframe and front suspension components
Fitting on RHD cars
Raise the subframe to about 100 mm from the bodywork. Fit the steering gear on the RH side and the collision guard in the subframe. Insert the bolts for the anti-roll bar's LH bearing with clamps. Tighten the two clamps to 50 Nm.
Fitting the subframe
Position engine lift 998 5972 under the LH side of the subframe.
Press the subframe up against the bodywork, fitting the steering gear bolts into the subframe at the same time.
Fit new bolts (M14) in the subframe. Oil the threads. Tighten the bolts to 105 Nm. Fit the support plate bolts at the same time.
RH side
Press up the subframe. Remove the old bolts and fit new ones in the same way as on the LH side.
Remove the engine lift.
Finally, tighten the four subframe bolts to 120°.
Tighten the support plate bolts to 50 Nm.
Fitting steering gear/subframe components
Fit:
- new locknuts and the steering gear bolt. Tighten to 50 Nm
- the front engine pad retaining bolt. Tighten to 50 Nm
- new torque rod attachment bolts. Tighten to 35 Nm + 40°
- the servo oil pipe retaining bolts.
Fitting the collision guard over the steering gear (RHD cars only)
Tighten the two bolts to 80 Nm.
Fit a new collision guard/subframe locknut. Tighten to 50 Nm.
Fitting the ball joint to the stub axle
Clean the ball joint and stub axle, removing all rust.
Lubricate the ball joint stud and stub axle.
Fit the ball joint in the stub axle.
Note: Press the ball joint up until the tapered top is visible above the bolted joint on the stub axle.
Fit:
- the ball joint bolt. Use a new nut. Tighten to 50 Nm
- the anti-roll bar link. Use a new nut. Tighten to 50 Nm
- tie rod with a new nut. Tighten to 70 Nm.
Fitting subframe components
Fit:
- the cable conduit on the subframe
- the carbon filter canister. Clamp the hoses on the subframe with cable ties. Hook the hoses on the subframe.
- the bracket and bolt for the ground cable.
Fitting the front casing and wheels
Fit:
- the front casing. Press the front edge into position. Press it forwards. Press the rear edge upwards so that the casing guide enters its groove. Fit the screws.
- the wheel.
Lower the car to the floor
Removing lifting yokes and lifting hook
Bend in the lug on the cable harness retainer.
Fit the bolt for the selector lever position sensor/retainer. Tighten it to 25 Nm.
Fit the control shaft lever. Tighten the nut to 16 Nm.
Assembling connectors
Fit the socket for the oil temperature sensor together with the other sockets.
Fit the sockets in the shell.
Fit the rubber seal in place.
Fit cable ties round the cable harnesses and the rubber seal.
Fitting connector end cabling
Fit:
- the connector to the transmission and the bracket with the connector. Tighten to 25 Nm
- transmission cabling to the connectors
Fit the gear selector cable with bracket. Tighten to 25 Nm. Connect the cable to the lever.
Fitting engine compartment components
Fit:
- the battery tray
- the air filter housing and inlet pipe
- the battery.
Fill with fresh oil, part number 1161540-8, using the same amount as noted earlier.
Top off and check the level.
Note: When changing the transmission fluid, the "Transmission fluid, change" counter should be reset to zero. Use VADIS vehicle communication to reset the counter.