Removing Turbocharged Engines With the Transmission
Removing Turbocharged Engines With The Transmission
Special Tools: 999 2810, 5185, 5462, 5474, 5488, 5533, 5642, 5666
Radiator and engine, draining coolant
Drain the coolant.
Removing the left-hand side drive shaft nut
Remove the hub cap. Remove the nut.
Removing the air conditioning (A/C) hose from the fan shroud
Removing the front and rear splash guards under the engine
Removing the lateral strut
Removing the front-rear member
Remove:
- the heat deflector plate
- the nuts for the engine pads
- the front and rear screws
- the two screws from the engine pads. Lift the front-rear member down from the car.
Removing the down pipe from the exhaust manifold
- Remove the nuts
- Pull the front exhaust pipe downwards
- Remove the gasket.
Removing the rear engine mounting
Remove the four screws. Remove the engine bracket.
Removing the front engine mounting
- Remove the clamps from the charge air cooler (CAC) hose.
- Remove the three screws and the engine mounting.
Removing the poly V-belts
- Relieve the load on the belts by turning the belt tensioner counterclockwise
- Remove the poly V-belts. Move it upwards.
Removing the air conditioning (A/C) compressor
Unscrew the upper screw from the mounting for the power steering pump.
Remove:
- the connector (A)
- the four mounting screws
- the compressor. Turn the compressor upwards as far as possible
- Move the mounting to one side.
Tie the front edge of the compressor to the car body.
NOTE: Do not damage the A/C hoses and pipes.
Removing the oil pressure sensor and generator (GEN) connectors
Remove:
- the connector from the oil pressure sensor
- the cable clamp from the bracket
- the connector in the middle.
Removing the right-hand drive shaft from the transmission
Remove:
- The drive shaft bearing cap on the engine side
- Both the front wheels
- The brake hose clips. Lift out the hoses from their mountings
- The ABS lines from its mountings
- The two nuts and the upper screw from the spring strut
- The wheel spindle from the spring strut (turn it)
- The drive shaft from the transmission
- The lower screw. Move the drive shaft to one side.
Insert special tool 999 5488 into the transmission.
Secure the wheel spindle using the lower spring strut screw.
Tie the drive shaft to the wheel arm.
Removing the left-hand side cover
Remove the screws. Lift off the cover.
Removing the left-hand side drive shaft assembly
Remove:
- The brake hose clips. Lift out the hoses from their mountings
- The ABS lines from its mountings
- The center nut from the drive shaft
- The two nuts and the upper screw from the spring strut
- Detach the drive shaft from the transmission. Use special tool 999 5462
- The drive shaft assembly
- Insert special tool 999 5488 into the transmission
- Secure the wheel spindle using the lower spring strut screw.
Automatic transmission: Disconnect the transmission oil pipes
- Disconnect the oil pipe terminals from the transmission. Move the pipes to one side.
- Ensure that no dirt gets into the transmission and hoses.
- Seal all openings using plastic plugs.
NOTE: Do not remove the hoses from the pipes.
Draining the fuel injection system
Drain the fuel injection system.
Removing the battery and battery shelf
- Remove the battery.
NOTE: If the car has cruise control, remove the vacuum hose and the connector before the vacuum pump is detached.
- Remove the screws from the battery shelf.
- Release the cable harness from the clamp.
- Remove the hose clamp from the battery shelf.
Removing the air cleaner (ACL)
Remove the air cleaner (ACL).
Disconnect The Battery Positive And Negative Leads
- Disconnect the connector (A).
- Remove:
- The nut and the battery positive lead
- The ground lead from the transmission.
Removing the gear selector mechanism cables
Automatic transmission
- Remove the gear selector cable mountings.
- Disconnect the connector.
- Remove the gear selector cable from the gear selector bevel arm on the transmission.
Remove the connectors from the transmission:
- Remove the gear selector cable from the transmission
- The ground lead from the transmission
- Remove the bracket for the connector from the transmission
- Separate the connector.
Removing the vacuum hose from the canister purge (CP) valve
Removing hoses from the turbocharger (TC)
Remove:
- The charge air pipe between the throttle body (TB) and the charge air cooler (CAC)
- The hose for the idle air control (IAC) valve at the charge air cooler (CAC)
- The hose at the pipe
- The screw for the bracket. Remove the pipe assembly together with the hose.
Removing the throttle cable
Remove:
- the cover by removing one screw and two plugs
- the cable with the throttle in the wide open position
- the retaining clip. Remove the cable sleeve.
Removing the cover, the mounting and the connectors
Remove The Connectors For:
- the engine speed (RPM) sensor
- the camshaft position (CMP) sensor
- the knock sensor (KS)
- the cable harness.
Remove:
- the protective tube from the 3 clips
- the brake servo hose from the power brake booster (press in the snap-ring and pull out the hose)
- the hose from the valve for the air cleaner (ACL).
Removing the fuel line from the engine
- Press the lock facing together. Pull out the fuel line
- Disconnect the pipe from the clamps. Move the pipe to one side.
Removing the cable harness
Disconnect the connectors from the engine.
NOTE: Note the position of all the mounting points for the cable harness.
Remove:
- the engine coolant temperature (ECT) sensor
- the cable from the bracket
- the cover over the injectors (pull the cover off)
- the injectors -the throttle position (TP) sensor
- idle air control (IAC) valve
- the cable guide by slackening off one screw and a nut
- the switch for the tail lamp
- move the entire cable harness to one side.
Removing the coolant hoses
Remove:
- the clamps
- the upper radiator hose
- the lower radiator hose on the engine side.
Removing the heater hoses from the engine connection
Remove:
- slacken off the hose clamps (make a note of how the hoses are routed)
- pull off the heater hoses.
Removing the power steering pump from the engine
- Remove the brackets between the power steering pump and the intake manifold and the lower bracket
- Remove the Poly V-belt
- Remove the mounting screws between the spokes on the pulley
- Remove the oil reservoir from the bodywork. Release the hose from the clips
- Remove the power steering pump. Place the pump to one side.
Place the hood in the service position
- Remove the two screws.
- Remove the support on the body side.
- Support the hood.
Removing the engine with the transmission
- Hang lifting hooks 999 5185 and 999 5642 on 999 2810.
- Raise the lifting equipment until it takes the strain off the engine.
- Remove the engine mounting on the transmission side:
- Remove the nut and the screw
- Remove the three screws. Remove the transmission bracket.
- Remove the engine mounting from the upper timing belt cover.
NOTE: Check carefully that the driveline is clear of the bodywork and other optional equipment. Turn the clamp at the oil cooler if necessary.
- Lift out the engine.
- Adjust the lifting equipment continuously throughout the lift.
- Return the hood to the normal position.