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Power train removal

Power train removal

To remove

Warning

A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!



1. Place the car on a lift and apply wing covers.

2. Open the cap on the expansion tank.


3. Remove the battery cover and disconnect the negative cable.

4. Raise the car slightly and remove the front wheels.

5. Remove the lower spoiler shield. Unplug and remove the connector.


6. Detach and plug the headlight washer hose.

7. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.


8. Close the cock and remove the hose.

9. Remove the right wing liner and detach the front part of the left wing liner.


10. CV : Remove Chassis reinforcement, front subframe, CV, petrol .

All : Relieve the load on the belt tensioner. Use a 1/4 " puller handle and remove the drive belt from the A/C compressor pulley.


11. Lower the car slightly and remove the bumper.

12. Remove the cover on the left-hand side.


13. Remove the charge air hose between the charge air pipe and the intercooler.

14. Remove the lower charge air pipe bracket from the fan cowling.

15. Remove the cover on the right-hand side.


16. Detach the hose from the charge air cooler.

17. Remove the dryer filter bolts from the radiator.

18. Detach the oil cooler's coolant hose from the radiator.

19. Remove the rear catalytic converter.


20. Place a receptacle under the car and remove the coolant connection. Move the hose aside.


21. Lower the car and remove the upper engine cover.

22. Remove the battery.

23. Undo the main fuse box in front of the battery tray and move it aside.


24. Remove the filler pipe of the washer fluid reservoir.

25. Detach the fuse holder from the battery tray.


26. Remove the cable duct from the battery tray.

27. Unplug the bonnet switch connector, undo the cable clip and remove the battery tray.

28. Detach the turbocharger intake manifold from the radiator member.


29. Undo the bonnet cable quick-release coupling by first undoing the clip in the body and then separating the quick-release coupling. Use a screwdriver.


30. Detach the right-hand headlight and pull it out slightly.

31. Detach the horn connector.


32. Remove the upper radiator member.


33. Unplug the connector from the mass air flow sensor.


34. Remove the dipstick tube's breather hose and the ventilation hose of the turbocharger.

35. Remove the secondary air pipe from the turbocharger intake manifold.

36. Remove the turbocharger intake manifold.

37. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.

38. Unplug the connector and undo the clips securing the cables on the fan cowling.


39. Remove the seal over the radiator assembly.

40. Remove the upper radiator brackets from the body.

41. Detach the upper radiator hose from the engine.

42. Remove the fan cowling retaining bolts.

43. Move the radiator assembly forward slightly and lift out the fan cowling.

44. Place a receptacle under the radiator and remove the lower radiator hose. Aut: Detach the oil pipes from the radiator using 87 92 806 Removal tool, oil pipes, automatic transmission . Plug the pipes.


45. Detach the boost pressure sensor connector (688).


46. Remove the charge air pipe between the throttle body and charge air cooler.

47. Detach the breather hoses from the coolant reservoir.


48. Remove the cover on the main fuse box and undo the two retaining bolts.


49. Disconnect the positive cable from the battery.

50. Undo the retaining bolt on the engine harness connector in the main fuse box.

51. Remove the engine harness clamp from the body and detach the ground cables.


52. Unplug the two connectors on the structural member.

53. Move the engine harness up and secure it to the engine with a cable tie or the like.

54. Check and adjust the steering wheel and the steering assembly so that they are pointing straight ahead.

55. Raise the car.

56. Detach the steering shaft from the steering gear.


57. Detach the power steering pipes from the radiator assembly.


58. Unplug the A/C compressor connector and remove the A/C compressor retaining bolts.


59. Fit 83 96 152 Centring tool, power train and 32 025 059 Support on the subframe. Adjust the tool approx. 10 mm to relieve some pressure on the engine mounts.


60. Undo the drive shaft's centre nuts. Detach the drive shafts from the hub. Use 89 96 951 Puller, drive shaft or a brass drift and mallet.


61. Undo the nuts and the outboard steering links from the steering swivel member with 87 91 287 Puller, 150 mm .

62. Remove the lower spindle joints' bolts on both sides.

63. Undo the lower anti-roll bar links while gripping the flats with a thin spanner.

64. Detach the angle sensor connector and detach the cable from the subframe.

65. Lower the car.

66. Detach the coolant hose and undo it from the holder on the engine.


67. Detach the brake servo vacuum pipe and move it aside.


68. Relieve excess pressure in the fuel system by carefully pressing on the needle of the service valve. Catch any fuel spill. Detach the fuel line from the fuel rail. Plug the fuel lines using 82 92 948 Plugs, A/C system, kit .

69. Release the quick coupling of the breather line and move it aside.

70. Remove the right-hand engine mounting.


71. Remove the left-hand engine mounting.


72. Detach the shifter cables from the gearbox; carefully move them aside and secure them to a brake pipe with a cable tie. Aut: detach the breather hose of the automatic transmission.


73. Man: Fit 30 07 739 Hose pinch-off pliers to the clutch hose and disconnect the quick coupling from the clutch slave cylinder.

74. Place the radiator member back in position.

75. Fit 2 83 95 212 Strap in the radiator member in order to secure the radiator assembly. Insert one strap around the radiator assembly. Insert the other and wrap an extra loop around the A/C compressor in order to relieve the load. Place a cardboard disc or the like between the A/C compressor and the radiator as support.

76. Place 83 96 145 Centring tool, subframe - engine on the trolley lift. Make sure the adjuster screws on the height adjusters, part no. 83 95 170, are in their lowest position. See "Centring tool, engine and subframe".

77. Position the trolley lift; raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters, part no. 83 95 170, so that they rest evenly on the subframe. Check with the body guide pins that the subframe is positioned correctly in relation to the body. See "Centring tool, engine and subframe".


78. Raise the trolley lift slightly to provide steady contact. Undo the rear bolts of the subframe stay and move the stay aside. Remove the subframe bolts from the body.

79. Carefully low the power train using the trolley lift. Detach the lower spindle joints from the steering swivel members and move aside the suspension arms. Make sure that nothing catches or gets damaged.