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Removing the power train

Removing the power train


Warning

A large number of hoses, electrical leads etc. are secured with cable ties. When these ties have been pulled tight, the excess is cut off and may leave sharp edges at the fixing points.

Beware of injuries like cuts and scratches caused by these sharp ends!



1. Cover the wings and remove the battery. Make a note of the radio code if necessary.


2. Open the coolant drain plug and drain the coolant. Remove the cap from the expansion tank to speed up draining.

3. Remove the air cleaner complete with hoses. Remove the engine cover or, alternatively, the resonator.


4. Disconnect the throttle cable and move it aside.

5. Undo the cruise control wire from the throttle body, unplug the cruise control electrical connection, undo the retaining screws and remove the cruise control unit complete with cable.

6. Detach and plug the fuel hoses. Use tool part no. 83 95 261 .

7. Detach the tank ventilation hose and bend it to one side.

8. Detach the pressure sensor and lay it on the engine (turbo).

9. Detach the vacuum hose for the secondary air injection (certain cars) and the vacuum hose for the brake servo from the intake manifold.

10. Remove the boost pressure control valve and lay it on the engine (turbo). Remove the heat shield (turbo).


11. Relieve the pressure on the belt tensioner using a ratchet handle extension and insert a 6 mm drill into the hole.


Important

Exercise the utmost care to ensure that the belt tensioner does not break at its end position!


12. Remove the power steering pump from its bracket and place it out of the way.

13. Remove the pressure pipe between the charge air cooler and the throttle body (turbo).

14. Detach the coolant hoses.


15. Remove the hose for the secondary air injection (certain cars).

16. Unplug the A/C compressor electrical connection and remove the top retaining bolt on the compressor.

17. Remove the positive cable from the plus terminal (follows with the engine) and undo the ground cable on the gearbox.


18. Remove the ignition lead and the electrical connections on the ignition coil (B204i).

19. Unplug the gearbox electrical connectors and lay them on the engine.

20. Disconnect the oxygen sensor cable.


21. Detach the ventilation hose from the gearbox and plug the hole (aut.).

22. Detach the gear selector cable (aut.) or alternatively separate the selector rod (man).

23. Depress the clutch pedal approx. 50 mm with a brake pedal clamp. This will prevent brake fluid from running out of the reservoir. Remove the retaining clip from the slave cylinder and disconnect the pressure pipe. Replace the retaining clip.


24. Remove the glove box (LHD) or, alternatively, the lower section of the dashboard on the right-hand side (RHD), fold back the floor mat and undo the central locking system control module. Detach the wiring harness to the engine.


25. Withdraw the wiring harness through the grommet to the engine bay and place it on top of the engine. Don't forget the cable to the boost pressure control valve (turbo).


26. Undo the hub centre-nuts on both sides and raise the car.


27. Remove both the front wheels and remove the hub centre-nuts. Undo the brake callipers and hang them from the MacPherson struts. Undo the track rod end nuts on both sides.

28. Remove the covers in the wheel housings and the air shields.

29. Undo the clamp between the front pipe and the intermediate pipe.


30. Detach the front exhaust pipe from the exhaust manifold or, alternatively, the turbocharger.

31. Detach the catalytic converter from its mounting and remove the exhaust pipe.

32. Place a vessel under the gearbox and detach the oil hoses, plug the holes. Place the hoses out of the way (aut.).

33. Remove the pipe between the turbocharger and the charge air cooler (turbo).


34. Detach the oil hoses to the oil cooler and plug the hoses (turbo).

35. Place the lifting trolley under the car so that the supports are centred under the front engine mountings and the gearbox. Remove the bolts on the subframe and the front engine mountings.


36. Lower the lifting table and thus also the engine and subframe. Remove the track rods and drive shafts on both sides. Use 89 96 696 Puller .


37. Detach the A/C compressor and hang it from the towing eye.

38. Lower the lifting trolley completely and remove the subframe by undoing the rear engine mounting from the gearbox.