Engine/Transmission, Removing
Engine/transmission, removing
Special tools:
999 5666 Wrench 999 5666 Wrench
999 5722 Wrench 999 5722 Wrench
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 battery negative lead. First read Battery, disconnecting Battery Disconnecting
- the cross stay between the suspension turrets
- the turbocharger control valve from the air cleaner (ACL). Disconnect the connector for the mass air flow (MAF) sensor. Slacken off the hose clamp on the mass air flow (MAF) sensor
- mass air flow (MAF) sensor connector
- the brake vacuum hose from the air cleaner (ACL)
- the air cleaner (ACL) assembly. Seal the openings in the intake pipe for the turbocharger (TC)
- the plastic charge air pipe above the engine. Seal the opening in the turbocharger (TC)
- the ground strip at the top/rear of the cylinder head.
Draining coolant
Open the cap on the expansion tank.
Position a container under the radiator drain cock.
Drain the coolant.
Warning! Avoid skin contact with the coolant.
Close the cock.
Draining the fuel system
Drain the fuel injection system. See Fuel system pressure release. See also: Fuel system, quick-release connectors.
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
- the ground lead at the front frame member.
Removing components from the transmission
Block the hose between brake the fluid reservoir and the clutch master cylinder.
Remove:
- the clutch hose from the junction. Plug the openings against dirt. Wipe up any spilled brake fluid
- the ground lead from the transmission and the sub-frame.
Cars with automatic transmissions
Remove the oil cooler hoses from the transmission. Plug the openings in the radiator and transmission.
Removing the mechanical transmission cables from the transmission
Caution! When working with the wires, ensure that the wire conduits do not crack or break.
Manual transmissions
Remove:
- the gear selector cables from the levers. Use jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar
- the mechanical cables from the bracket by moving the sleeves back on the cables.
Automatic transmission
Remove the screws for the transmission cable bracket at the transmission
Tie up the cables.
Disconnect the connector for the temperature and pressure sensor on the charge air cooler (CAC) outlet.
Remove:
- the rubber hose at the intake for the charge air cooler (CAC)
- the dip stick pipe
- the brake vacuum hose at the intake manifold
- the lower engine coolant hose from the engine
- the plastic pipe between the throttle body (TB) and the charge air cooler (CAC).
Hint: Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun.
Disconnect the wiring from the front heated oxygen sensor (HO2S). Remove the wiring from the clips and clamps.
Removing components
Disconnect the connector for the level sensor in the expansion tank.
Remove:
- 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 from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.
Remove:
- control module unit cover
- the control modules. Use brace 999 5722 Wrench 999 5722 Wrench
- the surround for the control module box.
Removing the connector with cable and cable protector
Remove:
- the red retaining clip for the connector using a screwdriver
- the connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver.
Lift up the connector with the protection underneath and put it to one side.
Remove the ground lead from the right-hand fender liner. Slide out the wiring between the front cover plate and the air conditioning (A/C) pipe.
Exposing the air conditioning (A/C) compressor
Caution! Handle the compressor carefully so that no kinks are created in the AC-pipes.
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.
Removing components
Remove the ignition key.
Raise the car.
Remove:
- the left and right front wheels
- the splash guard under the engine
- the splash guard under the engine (Only applies to cars with automatic transmissions).
Separating the steering shaft
Remove the screw from the joint between the steering gear and the steering shaft.
Caution! The steering shaft must not be turned. The contact reel in the SRS-system may be damaged.
Remove the nut on the tie rod from the wheel spindle (on the left and right-hand sides).
On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement. Press up the joint from the steering gear.
Removing front suspension components (both sides)
Disconnect the ABS line from the mounting in the spring strut.
Remove:
- the screw for the drive shaft using a screwdriver in the brake disc vents
- the link from the anti-roll bar
- the nut for the ball joint and link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.
Note! Counterhold with a Torx TX 40 in the ball joint top when removing the nut. This is so that the ball joint gaiter does not turn.
Separating the fuel line
Note! If an engine heater is installed, mark up the the fuel lines.
Separate the quick-release connectors for the fuel pressure line and engine block heater (option).
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.
Removing the three-way catalytic converter (TWC)
Remove the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing, B5244T5, B5254T2 Service and Repair.
Removing the propeller shaft
Remove the propeller shaft. See Propeller shaft, replacing, B5254T2, M58, B5254T2, AW50/51 AWD Propeller Shaft.
Lowering the engine and transmission
Use a post hoist with a lifting table and stud guides. Anchor 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.
Caution! Make sure that no hoses, wiring or anything else catches in the engine and transmission unit when it is lowered.
Remove:
- the screws for the sub-frame brackets
- 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.
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.
Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and transmission unit.
Removing the engine coolant heater (option)
Remove:
- the bumper cover on the left hand side. Use a weatherstrip tool
- the M8 nut at the top of the left-hand fender liner for the engine coolant heater
- the connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.
Remove:
- the screws for the sub-frame brackets
- 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 in the engine and transmission unit when it 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.