Engine/Transmission, Removing: Removal

SAFETY 

REMOVING COMPONENTS 

Remove: 

• the battery negative lead. First read, see BATTERY, DISCONNECTING
• the engine stabilizer brace between the suspension turrets
• the engine cover by pulling it straight up
• the cover over the central electrical unit
• the connector for the engine cable harness from the central electrical unit
• the positive lead for the starter motor from the terminal block
• the connector on the mass air flow (MAF) sensor
• the turbocharger control valve from the air cleaner (ACL). Disconnect the connector
• the intake pipe between the air cleaner (ACL) and the front cover plate
• the hose and hose clamp for the turbocharger (TC) inlet hose
• air cleaner (ACL) assembly
• the gear selector cables
• the ground lead between the engine and the left-hand frame member
• separate the transmission wiring
• the brake vacuum sensor on the vacuum pump.

DRAINING COOLANT 

Position a container under the radiator drain cock.

Drain the coolant.

Remove: 

• the screw for the front exhaust pipe and support bracket
• the 3 nuts that hold the front exhaust pipe to the turbocharger (TC).

  HINT: Tie up the front exhaust pipe at the right suspension turret 

• the front SIPS member
• the propeller shaft. See PROPELLER SHAFT, REPLACING .
  CAUTION: Mark the flange in relation to the propeller shaft joint.

Remove: 

• the passenger compartment heater hoses
• the engine coolant hose between the expansion tank and the engine
• the ABS line and clips from the power steering hose. Lift the power steering reservoir. Place it on top of the engine.

Remove: 

• the cover for the control module box
• the control modules. Use mounting bracket see 9995722
• the surround for the control module box.

REMOVING THE CONNECTOR, CABLE AND CABLE SLEEVE 

• Remove the red retaining clip from the connector using a screwdriver
• Disconnect the connector by releasing the catches at the front edge using pliers. Gently pry out the connector using a screwdriver
• Lift the connector up and out with the protection underneath and put it to one side
• Remove the ground lead from the right-hand fender liner
• Pull out the wiring between the front cover plate and the air conditioning (A/C) pipe.

DISCONNECTING THE CONNECTOR 

Remove: 

• the right-hand headlamp by pulling up the two lock facings straight up and disconnecting the wiring. Place the headlamp to one side
• the connector for the air conditioning (A/C) receiver drier
• the gray connector for the fan shroud
• the connectors for the pressure and temperature sensors on the charge air cooler (CAC)
• the charge air pipes between the engine and charge air cooler
• the upper coolant hose on the engine. Push to one side
• the lower coolant hose from the radiator
• the oil coolant hoses from the oil cooler.
  CAUTION: Seal the openings.

EXPOSING THE AIR CONDITIONING (A/C) COMPRESSOR 

• Unhook the auxiliaries belt
• Disconnect the one-pin connector for the compressor magnetic clutch
• Remove the 4 screws holding the compressor to the engine
• Tie up the compressor in the front cover plate.

REMOVING THE LOWER STEERING SHAFT JOINT 

• Remove the soundproofing panel under the steering wheel
• Fold back the floor carpet
• 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. The contact reel in the SRS (supplemental restraint system) could be damaged.
• Remove the screw from the joint in the mounting for the steering shaft
• Remove the joint from the steering shaft by pressing the shaft upwards.

REMOVING COMPONENTS 

Raise the car.

Remove: 

• the left and right front wheels
• the splash guard under the engine.

REMOVING THE FRONT SPLASH GUARDS 

• Remove the 6 screws
• Lift up and slide the plate forward
• Remove 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.

REMOVING COMPONENTS CONTINUED 

Remove the tie rod from the wheel spindle. On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.

Remove: 

• the link rod from the anti-roll bar
• the sound insulation cover for the drive shaft
• the nut holding the control arm to the ball joint
• the center screw and the end of the drive shaft.

SEPARATING THE FUEL LINE 

Separate the quick-release connectors for the fuel lines to the engine and engine block heater. Also, see FUEL SYSTEM, QUICK-RELEASE CONNECTORS .

LOWERING THE ENGINE AND THE TRANSMISSION 

Use a post hoist with a lifting table and stud guides.

Secure the lifting table against the sub-frame.

REMOVING THE ENGINE COOLANT HEATER 

Remove: 

• the bumper cover on the left hand side. Use a weatherstrip tool
• M8  nut at the top of the left-hand fender liner for the engine coolant heater
• the connector for the engine coolant heater.

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
• 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.