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Power train removal

Power train removal


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

2. Open the cap on the expansion tank.


3. Remove the upper engine cover, insulation and battery cover.

4. Remove the battery cable.

5. Remove the battery.

6. Remove the glow plug control module and fuse holder from the battery tray.


7. Unplug the bonnet switch connector and remove the battery tray.

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

9. Raise the car and remove the lower engine cover as well as the front spoiler shield. Unplug and remove the connector.


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

11. Remove the wing liners from both front wheel housings.


12. Undo the gearbox drain plug and drain off the gearbox oil.


13. Fit the drain plug.

Tightening torque 50 Nm (37 lbf ft)

14. Detach the headlight washer hose and plug the washer fluid reservoir.


15. Lower the car slightly and remove the bumper.


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


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

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

19. Remove the cover on the right-hand side and remove the connectors and clips from the engine control module.


20. Remove the bracket for the engine wiring harness.


21. Lower the car.

22. Remove the right-hand headlight.

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

24. Detach the A/C pipe mounting from the upper radiator member.


25. Undo the connector and remove the turbo solenoid valve.

26. Remove the upper radiator member and the horn connector.


27. Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe upper retaining bolt.


28. Remove the turbo delivery pipe and hose from the turbocharger outlet.

29. Remove the upper radiator hose.

30. Detach the bleeder hose from the radiator. Aut: Detach the oil pipes from the radiator using 87 92 806 Removal tool, oil pipe, automatic transmission .


31. Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold.

32. Remove the upper radiator mountings.


33. Hold away the A/C hose using 83 95 212 Strap .


34. Remove the electrical connection from the fan cowling.

35. Remove the bolts and lift up the fan cowling.

36. Remove the turbocharger intake hose.


37. Remove the mass air flow sensor connector, air cleaner casing cover and air filter element.

38. Detach the intake hose and remove the air cleaner casing.

39. Remove the turbocharger intake manifold. Detach the crankcase ventilation hose.


40. Detach the lower radiator hose from the engine.

41. Disconnect the hose with quick coupling from the vacuum pump.


42. Detach the connector from the left structural member.


43. Remove the windscreen washer filler pipe.

44. Remove the cover on the main fuse box and undo the two retaining screws.

45. Disconnect the positive cable from the battery.

46. Undo the screw securing the engine wiring harness connector in the electrical centre.

47. Remove the engine harness clamp from the body and the ground cables.

48. Unplug the connectors of the particle filter pressure sensor and the temperature sensor.


49. Remove the engine wiring harness from the right structural member and lift it onto the engine.


50. Fold up the engine wiring harness onto the engine.

51. Undo the coolant level sensor connector. Detach the expansion tank from the body and remove the tank together with the hose.


52. Remove the gear cables from the gearbox. Carefully bend the cables aside and secure them to the expansion tank bracket on the body using a cable tie.


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

54. Undo both fuel lines. Collect any fuel spill. Plug the fuel lines. Use 82 92 948 Plugs, A/C system, kit .


55. Undo the quick coupling on the right-hand coolant hose and the clips on the bulkhead. Catch any spilt coolant. Bend aside the hose and attach it to the engine.

56. Option: Undo the coolant hose leading to the parking heater on the thermostat housing. Secure the hose to the bulkhead.


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

Warning

In order to avoid the contact roller for the airbag twisting and breaking the steering wheel must be secured via the steering column lock or by taping it to the panel.


58. Raise the car.

59. Detach the steering shaft from the steering gear.


60. CV : Remove Chassis reinforcement, front subframe, CV, diesel .

All : Remove the poly-v-belt. Mark the belt's direction of rotation.


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


62. Undo the drive shaft centre nuts. Knock loose the drive shafts from the hubs. Use 89 96 951 Puller, drive shaft or a brass drift with mallet.


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

64. Disconnect the lower links of the anti-roll bar. Use a thin wrench in the keys to hold them still.

65. Option: Remove the connector for the headlamp angle sensor and undo the cable from the subframe. Remove the bracket from the suspension arm.


66. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.

67. Undo the drive shafts and move them away.

68. Remove the right-hand drive shaft.


69. Remove the intermediate shaft and bracket.


70. Up to and including Vehicle Identification Number 71107671: Remove the oil sump's insulation.


71. Remove the front exhaust pipe.


72. Fit 83 96 145 Centring fixture, subframe - engine with 83 96 368 Supplement kit to centring fixture and 32 025 007 Assembly fixture on the subframe. Due to tight tolerances on the drive shafts, the centring tool must be used to ensure that the power unit is accurately fit to the subframe and body when refit.


73. Lower the car.

74. Place the radiator member back in position.

75. Fit 2 x 83 95 212 Straps to the radiator member. Lower one strap down around the radiator assembly. Wind an extra time around the A/C compressor to take the strain.


76. Undo the left and right-hand engine mountings.


77. Raise the car.

78. Place 83 96 145 Centring fixture, subframe - engine on the trolley lift. Make sure that the adjustment bolts on the 83 95 170 height adjusters are fully lowered.

79. 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 83 96 152 Centring tool, power unit .

80. Raise the trolley lift slightly so that it is firmly pressed against the subframe. Undo the bolts securing the subframe and subframe stay to the body.


81. Carefully lower the power train on the trolley lift, making sure nothing gets caught or damaged.