Engine/Transmission, Removing
Engine/transaxle, removing
Special tools:
999 5543 Socket NV-22 HO2S 999 5543 Socket NV-22 HO2S
999 5722 Wrench 999 5722 Wrench
999 5259 Separator 999 5259 Separator
Preparation
Note! Since 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.
Remove:
- Remove the cable from the battery negative terminal. First read Battery, disconnecting Battery Disconnecting
- The expansion tank cap.
Draining the refrigerant from the climate control unit
See Refrigerant, draining Refrigerant, Draining
Removing the protective plate
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Remove the 6 screws.
Lift and slide the splash guard forward.
Remove the protective plate.
- Remove the splash guard under the engine.
- Disconnect the connectors for the heated oxygen sensors. Remove the wiring from the clips and tie straps.
- Connect a hose to the engine coolant drain cock.
- Drain the coolant into a clean container. Close the cock.
Removal of charge air pipe
Remove:
- the screw for the engine stabilizer brace mounting on the engine
- the cross stay between the suspension turrets
- the plastic charge air pipe over the engine
- the charge air pipes which connect to the turbocharger (TC). Seal the openings
- the air cleaner (ACL).
Removing heated oxygen sensors (HO2S)
Note! Note the position of the probes to make it easier to reinstall them. If they are mixed up, diagnostic trouble codes may be stored.
Slide the wiring for the front catalyst monitor sensors upwards and unscrew them from the catalyst. Use tool 999 5543 SOCKET NV-22 HO2S 999 5543 Socket NV-22 HO2S
Removing heat deflector plates
- Remove the heat deflector plates from the turbocharger (TC)
- Remove the nuts from the flange between the turbocharger (TC) and the three-way catalytic converter (TWC).
Hint: Use easing oil on the stud bolts.
- Separate the connections. Unhook the three-way catalytic converter (TWC)
- Remove the ground strip between the engine and bodywork which is positioned above the turbocharger (TC) for cylinders 1, 2 and 3.
Removing components
Remove both the hoses for the heater unit on the bulkhead. Clean up any spilled glycol using paper.
Remove:
- the battery lead from the terminal block at the fusebox
- the connector in the fuse box.
Remove:
- the rear radiator hose at the transaxle
- the gear selector cable from the transaxle
- the connector for the input speed sensor on the transaxle
- the connector on the transaxle
- the vacuum hose on the intake for the servo unit
- the connector on the sensor in the charge air cooler (CAC)
- the ground lead from the engine to the car body (detach in the car body).
Remove the charge air pipe on the intake between the throttle module and the charge air cooler.
Hint: If necessary use a hot air gun to loosen the pipe.
Detach the upper radiator hoses on the engine.
- Lift the power steering reservoir. Place it on top of the engine.
Note! Make sure that no oil leaks out from the reservoir through the ventilation holes in the cover.
- Remove the coolant expansion tank. Slacken off the hose clamp on the hose to the engine. Disconnect the connector
- Remove the radiator breather tube by the expansion tank. Put the expansion tank to one side.
Removing control modules
Remove:
- the cover from the distribution box
- control modules using tool 999 5722 Wrench 999 5722 Wrench
- the surround from the distribution box.
Pry out the connector plate from the lower section of the control module box and pull the connectors of the engine and transmission wiring from the plate.
Detach the ground lead on the wing liner.
Caution! Seal the openings.
Separate the climate control unit pipe at the frame member inside the central electrical unit.
Removing headlamp
Remove the right-hand headlamp by pulling the 2 lock facings on the lamp straight up. Then carefully pull the headlamp forward. Disconnect the connector and lift out the headlamp.
Disconnect the connector from the sensor on the accumulator. Pull the wiring through to the engine compartment.
Removing the lower steering shaft joint
Set the front wheels so that they are straight
- Fold the floor carpet out of the way.
- Bend up the outer section of the steering shaft boot.
- Remove the retaining clip around the boot.
- Pull the boot up.
- Turn the steering wheel to gain the best possible access to the steering shaft nut.
- Remove the ignition key. Activate the steering wheel lock.
Caution! Do not move the steering wheel since the contact reel in the SRS-system may be damaged.
Remove:
- the screw securing the mounting for the steering shaft in the joint
- the joint from the steering shaft by pressing the shaft upwards.
Note! Clean and spray the exposed threads with rustproofing agent before beginning removal.
Carry out the following operations on the left and right-hand sides.
Remove:
- the front wheel
- the track rod ends from the steering arm. Use puller 999 5259 SEPARATOR 999 5259 Separator
- the screw holding the drive shaft to the hub.
- the nut of the ball joint/link arm.
- the nut for the anti-roll bar.
Note! Counterhold using Torx 40 so that the ball joint boot does not turn when the nut is removed.
Caution! The steering shaft must not be turned. The contact reel in the SRS-system may be damaged.
On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.
- Disconnect the brake pipe from the clips on the front SIPS member.
- Remove the 4 screws for the front SIPS member
- Remove the member.
- Unhook the three-way catalytic converter (TWC) from the rubber mounting.
Pay attention to the following when removing propeller shaft
Follow instructions. Refer to: Propeller shaft, special information Description and Operation
Removing the propeller shaft
Remove:
- the tie straps from the wiring for the rear probe. Separate the probe wiring
- the nut for the flange between the three-way catalytic converter (TWC) and exhaust system
- the propeller shaft. See Propeller shaft, replacing Propeller Shaft and Replacing the bevel gear/chain housing Replacing the Bevel Gear/Chain Housing
Draining the fuel line
- Depressurize the fuel system acc. to Fuel system pressure release Fuel System Pressure Release.
- Disconnect the fuel line quick-release connector at the engine
Note! Seal the openings against dirt.
- Put the line to the side.
- Separate the EVAP canister cable at the rear right sub-frame mounting
- Remove the transaxle oil cooling hoses from the gearbox. Seal the openings.
Lowering the engine/transmission unit
Caution! Make sure that the lifting table is properly centered under the engine.
Position a lifting table under the sub-frame. Secure the table against the sub-frame.
Caution! Do not damage the brake pipe that runs across the propeller shaft tunnel.
Remove:
- the screws of the subframe brackets.
- the screws for the sub-frame. Lower the engine and gearbox approximately 15 cm so that the drive shafts describe a horizontal line between the hub and gearbox.
Note! Take great care that no hoses, wiring, or anything else catches in the engine/transmission unit when it is lowered.
Unhook the link arms from the ball joint pin.
Remove the drive shafts from the wheel hubs.
Note! Do not pull on the drive shafts. They do not have axial locks. Do not damage the ABS-wiring. Do not damage the brake pipe.
Let the drive shafts rest against the control arms. Lower the three-way catalytic converter (TWC).
Continue lowering until the hose for the compressor in the climate control unit is accessible. Detach the inner hose for the climate control unit. Seal the openings. Continue lowering the unit.