Removal
Special tools
999 2810
999 5185
999 5462
999 5474
999 5488
999 5533
999 5642
999 5666
Draining coolant from radiator and engine
- See Replacing coolant, refer to Cooling System.
Undo drive shaft nut at the left side
Remove cover, undo nut.
Disconnect the air-conditioning (A/C) hose from the fan shroud
Remove engine splash guards front and rear
Remove crossmember stay
Remove longitudinal beam
Remove:
- the engine rubber heat shield
- the nuts from the engine rubbers
- the bolts front and rear
- the two bolts from the engine rubbers and remove the longitudinal beam from the car.
Remove exhaust down pipe from exhaust manifold
- Remove the nuts
- Pull the exhaust pipe downwards
- Remove the gasket.
Remove rear engine bracket
Remove the four bolts and the bracket.
Remove front engine bracket
Remove the clamps of the Charge Air Cooler (CAC) hose.
Remove the three bolts and take the bracket off.
Remove poly V-belt
- Loosen the belt tension by turning the spanner counterclockwise
- Remove the poly V-belt and move it upwards.
Remove the air-conditioning (A/C) compressor
Undo the upper bolt from the bracket at the power steering pump.
Remove:
- the connector (A)
- the four mounting bolts
- the compressor and turn it upwards as far as possible
- Move the bracket sidewards.
Tie the compressor up at body at the front side.
Note! Take care about the AC pipes/hoses.
Remove connector oil pressure sensor and alternator
Remove:
- the connector from the oil pressure sensor
- the cable clamp from the bracket
- the connector at the center.
Remove right hand drive shaft from transmission
Remove:
- The bearing cap at the engine side
- Both the front wheels
- The brake hose clips and take the hose out of the bracket
- The ABS wiring out of the bracket
- The two nuts and the upper bolt from the shock absorber
- The knuckle out of the shock absorber (turning)
- The drive shaft out of the transmission
- The lower bolt and move the drive shaft sideways.
Install special tool 999 5488 in the transmission.
Install the knuckle in the lower shock absorber bolt.
Tie up the drive shaft to the wheel arm while bringing shaft (drive) underneath.
Remove the side cover left side
Remove the bolts, take panel out.
Remove complete left hand drive shaft
Remove:
- The brake hose clips and take the hose out of the bracket
- The ABS wiring out of the bracket
- The central nut from the drive shaft
- The two nuts and the upper bolt from the shock absorber
- Undo the drive shaft from the transmission, use special tool 999 5462
- The drive shaft complete
- Install the special tool 999 5488 in the transmission
- Install the knuckle in the lower, shock-absorber mounting hole.
AT: Disconnect transmission oil pipes
Disconnect the oil pipe connections from the transmission and push them to one side.
Ensure that no dirt gets into the transmission and the hoses.
Seal all openings with plastic plugs.
Note! Do not remove the hoses from the pipes.
Drain fuel system
See Draining the fuel injection system, refer to Powertrain Management.
Remove battery and shelf
Remove the battery.
Note! If the car is fitted with cruise control, you must undo the vacuum hose and leads to the vacuum motor.
Remove bolts shelf.
Undo the cable harness out of the clamp.
Remove the hose clamp from the shelf.
Remove air cleaner (ACL)
Remove the Air Cleaner (ACL).
Remove positive and negative battery lead
Disconnect the connector (A).
Remove:
- The nut and remove the positive battery lead
- The ground lead from the transmission.
Remove gear shift mechanism cables
Remove: the gear selector cable support.
Disconnect the plug connector.
Remove the gear selector cable from the transmission.
Remove the connectors from transmission:
- The gear selector cable from the transmission
- The ground lead from the transmission
- Disconnect the connector bracket from the mounting on the transmission
- Separate the connector halves.
Remove hose from Canister Purge (CP) valve
Remove turbo hoses
Remove:
- The inlet hose from the Charge Air Cooler (CAC) to the Throttle Body (TB)
- The idling control-valve hose at the Charge Air Cooler (CAC)
- The hose at the pipe
- The bolt for the bracket and remove the complete pipe with the hose out.
Remove throttle cable
Remove:
- the cover by undoing one bolt and two plugs
- the inner cable at full throttle
- the clip and take the outer cable out.
Remove the bracket cover and connectors
Remove connectors for:
- the engine speed sensor
- the camshaft position sensor
- the Knock Sensor (KS)
- cable harness.
Remove:
- cable (protector) out of the clips (3x)
- the brake servo hose from the brake booster (press securing ring and pull hose out)
- hose from valve to air filter.
Remove fuel line from engine
- Press securing lips together, pull pipe out
- Pull pipe out clamps and move it sidewards.
Remove cable harness
Disconnect the plug connectors from the engine.
Note! Note all the positions of the cable harness mounting points.
Remove:
- the Engine Coolant Temperature (ECT) sensor
- cable out bracket
- remove injector cover (pull off)
- the injectors
- the Throttle Position (TP) sensor
- the Idle Air-Control (IAC) valve
- the cable guide by undoing one screw and one
- rear light switch
- move the whole cable sidewards.
Remove engine coolant hoses
Remove:
- the clamps
- upper coolant hose
- the lower coolant hose at the engine side.
Remove heater hoses from engine connector
Remove:
- loosen the clamps (note the route)
- pull off the hoses.
Remove power steering pump from engine
- Remove brackets between the pump and the inlet manifold and the lower bracket
- Take the poly V-belt out
- Remove bolts via the opening in the pulley flange
- Remove reservoir from the body and lift the hose out of clips
- Pull power steering pump off and place it to the side.
Place hood in service position
Remove the two bolts.
Remove the stand at the body side.
Support the hood.
Remove engine complete with transmission
Attach lifting lugs 999 5185 and 999 5642 to 999 2810.
Lift the engine up until it is under tension.
Remove the engine mounting on the transmission side:
- Remove the nut and the bolt
- Remove the three bolts and take the transmission bracket away.
Remove the engine mounting bolt on the distributor side.
Note! Check carefully to see that the complete transmission does not touch the body or any optional extras. If necessary turn the clamp at the oil cooler.
Lift the engine out.
Always adjust the tackle hook when lifting.
Place hood back in normal position.