Removal and Replacement
Engine/transmission, removing/installing
Special tools:
999 5562 PROTECTIVE SOCKET 999 5562 Protective Socket
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5488 PLUGS 999 5488 Plugs
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5722 Wrench 999 5722 Wrench
999 2810 LIFTING YOKE 999 2810 Lifting Yoke
999 5185 HOOK 999 5185 Hook
999 5464 LIFTING EYE 999 5464 Lifting Eye
999 5428 LIFTING YOKE 999 5428 Lifting Yoke
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Removal
Preparation
Remove:
- the battery negative cable. First read Battery, disconnecting Battery Disconnecting
- the expansion tank cap
- the air pre-heating hose
- the cross stay between the suspension turrets
- the engine positive lead from the terminal at the left suspension turret.
Drain the fuel system. See Fuel system pressure release Service and Repair.
Drain the fuel system, applies only to B5xx4S6. See Fuel system pressure release Service and Repair.
Separate the fuel line and EVAP line quick-release connector at the right rear subframe mounting. See also Fuel system, quick-release connectors Description and Operation.
Only applies to B5244SG and B5244SG2
Drain the gas line according to
Drain the fuel system according to Draining the fuel system Service and Repair
Note! Protect the openings against dirt. Place the lines to one side.Make sure that all cleanliness conditions for working with the fuel injection system are followed.
Remove the splash guard under the engine.
Position a container at the drain nipples to collect the coolant.
Open the nipples on the engine and the radiator.
Thread hoses onto the relevant nipple to collect the coolant.
Close the nipples.
Remove
- the right-hand drive shaft. See Drive shaft left, replacing Drive Shaft Left, Replacing
- the left-hand drive shaft. See Drive shaft left, replacing Drive Shaft Left, Replacing
- the screw for the lower torque rod in the transmission.
Note! Install sealing plugs 999 5488 PLUGS 999 5488 Plugs in the holes where the drive shafts were positioned.
- the lower screws of the front and rear engine mountings.
Separate the heated oxygen sensor (HO2S) connectors.
Remove the clamp for the mounting for the heated oxygen sensor wiring at the steering gear.
Release the heated oxygen sensor (HO2S) wiring from the rear engine mounting.
Remove the nuts where the manifold and the front exhaust pipe divide.
Remove the screws holding the SIPS member to the bodywork.
Press the brake pipe out of the holders on the SIPS member.
Press the exhaust system backwards. Remove the exhaust system from the manifold.
Ensure that you do not damage the heated oxygen sensor (HO2S) or the wiring.
Note! The metal hose for the front exhaust pipe is damaged very easily. Therefore it should be handled with great care to avoid leakage later on.
- the connector from the mass air flow (MAF) unit
- the connector from the air assisted control valve
- the intake hose between the air cleaner housing and the front panel.
- the intake hose from the air cleaner (ACL)
- the vacuum hose for control of preheated air
- the air cleaner assembly.
- the braided ground cable between the engine and the cowl panel.
- the heater hoses from the cowl panel
- the brake vacuum hose from the intake manifold.
Place it to one side.
Disconnect the connectors from the fan shroud.
Remove the canister purge (CP) valve.
Remove the manifold absolute pressure (MAP) sensor from the mounting at the front panel.
Disconnect the vacuum hose for the EVAP canister from the canister purge (CP) valve.
Place the wiring to one side.
Lift the hose for the expansion tank from the holders at the top edge of the fan shroud
Remove the screws for the fan shroud.
Lift up the engine cooling fan (FC) with the fan shroud.
Install radiator protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
Applies to cars with manual transmissions
Remove
- the lower radiator hose
- the ground lead on the transmission
- the mechanical transmission cables. Mark up the cables
- the rubber mounted section of the mounting for the mechanical gear selector cable.
Plug the hose between the brake fluid reservoir and the clutch master cylinder using hose pliers.
Disconnect the clutch cable.
Separate the terminal block at the bracket for the air filter
- the air filter bracket.
Applies to cars with automatic transmissions
Remove
- the lower radiator hose
- the two oil cooling hoses for the transmission from the radiator
- the ground lead on the transmission
- the mechanical gear selector cable.
Separate the terminal block at the bracket for the air filter
- the air filter bracket.
Remove
- the upper radiator hose from the thermostat housing
- the expansion tank
- the auxiliaries belt
- the three screws retaining the power steering pump.
Disconnect the temperature sensor cable from the bracket on the power steering pump.
Note! Leave the power steering pump in place for the moment.
Unplug the connector of the AC compressor's electromagnetic clutch.
Remove the four screws retaining the air conditioning (A/C) compressor in the engine.
Start with the lowest screws.
Note! Be careful so that the pipe does not break or crack when the upper screws are loosened.
Remove the compressor and hang it up on the front cover plate.
Note! Do not touch the pins on the control module with fingers. Static electricity may damage components in the control module.
Remove the cover from the control module box.
Insert tool 999 5722 Wrench 999 5722 Wrench around the control module.
Insert the upper section of the tool as far as it will go. Raise the tool.
Carefully pull up the control module.
Remove the intermediate section of the control module box.
Pry out the connector plate from the lower section of the control module box.
Disconnect the engine and transmission wiring connectors.
Place the engine and transmission wiring on top of the engine.
Lifting out the engine and transmission
Lift up the power steering pump and put it to one side.
Use lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke.
Fit hook 999 5185 HOOK 999 5185 Hook between the engine's lifting lugs at the auxiliaries bracket and the upper torque rod bracket.
Fit lifting lug 999 5464 LIFTING EYE 999 5464 Lifting Eye in the exhaust manifold.
Fit mounting bracket 999 5428 LIFTING YOKE 999 5428 Lifting Yoke to the hooks and lifting lug.
Lift out the engine.
Remove the front engine pad when lifting.
Adjust the lift angle throughout the lift.
A relatively large angle is required.
Note! Check carefully that the drivetrain goes clear of the bodywork and any optional equipment. Also make sure that no engine or transmission wiring catches during the lift.
Installation
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Reinstalling the engine and transmission
Use lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke , mounting bracket 999 5428 LIFTING YOKE 999 5428 Lifting Yoke , lifting lug 999 5464 LIFTING EYE 999 5464 Lifting Eye and two hooks 999 5185 HOOK 999 5185 Hook.
Align the lifting yoke so that the weight of the engine is evenly distributed.
Adjust the hoist angle throughout the lift.
Note! Check that the drivetrain goes clear of the bodywork and any optional equipment.
Tighten the nut of the front engine mounting.
Finishing
Install the engine and transmission wiring.
Plug in the engine and transmission wiring connectors to the connector plate.
Press the connector plate into place in the lower section of the control module box.
Install the intermediate section. Align the ventilation pipe at the rear edge of the control module box.
Screw the control module box into place in the fender liner.
Press the control modules down carefully.
Lock into place using mounting bracket 999 5722 Wrench 999 5722 Wrench.
Press the cover into place.
Install
- the air conditioning (A/C) compressor. Tighten to 25 Nm.
Plug in the connector of the AC compressor's electromagnetic clutch.
- the engine and transmission wiring in the mountings on the subframe.
- the power steering pump. Tighten to 25 Nm.
- the expansion tank and coolant hoses
- the upper radiator hose
- the auxiliaries belt
Applies to cars with manual transmissions
Install
- the air filter bracket. Connect the terminal block at the bracket for the air filter
- the ground lead on the transmission
- the lower radiator hose
- the rubber mounted mounting for the mechanical gear selector cables
- the mechanical transmission cables.
Connect the clutch cable. Use a new seal.
Note! Make sure that the clip locates in its channel.
Remove the lock grip pliers.
Bleed the clutch.
Applies to cars with automatic transmissions
Install
- the air filter bracket
Connect the terminal block at the bracket for the air filter
- the ground lead on the transmission
- the lower radiator hose
- the two oil cooler pipes to the radiator
- the mechanical transmission cable.
Remove radiator protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.
Install
- the engine cooling fan assembly with shroud.
- the air cleaner (ACL) assembly
- the canister purge (CP) valve in its bracket and connect the EVAP canister vacuum hose
- the manifold absolute pressure (MAP) sensor to the mounting in the front cover plate
- connect the engine cooling fan (FC) connectors. Clamp the wiring.
Install:
- the brake vacuum hose on the inlet pipe
- the heater hoses on the cowl panel
- the braided ground cable between the engine and cowl panel.
- the air cleaner (ACL) assembly
- the air preheating hose
- the vacuum hose for control of preheated air
- the intake hose between the air cleaner (ACL) housing and the front panel
- the inlet hose between the air cleaner (ACL) and the throttle body (TB).
Connect the connector for the HFM unit and the assisted air control valve.
Install:
- the front and rear screws for the engine mountings (A).
Tighten to 50 Nm.
- the screw for the torque rod in the transmission.
Use a new screw and nut.
Tighten the screws. Tighten to 35 Nm. Angle-tighten 90°.
- both the screws for the right engine mounting (B).
First bend the right fender liner slightly so that it is out of the way.
Lubricate the studs at the manifold. Use paste (P/N 116 14 08). Avoid skin contact with the paste!
Install
- the front exhaust pipe on the manifold. Use a new gasket and new nuts. Do not tighten!
- the screws securing the SIPS member to the bodywork
- the brake pipe in the holders at the SIPS member
Tighten the nuts where the manifold and the front exhaust pipe separate. Tighten the screws securing the SIPS member. Tighten to 25 Nm.
Secure the wiring for the heated oxygen sensors (HO2S) at the rear engine mounting and at the steering gear
- the right-hand drive shaft. See Drive shaft left, replacing Drive Shaft Left, Replacing
- the left-hand drive shaft. See Drive shaft left, replacing Drive Shaft Left, Replacing
- the wheels. See Installing wheels Service and Repair.
Install the engine positive cable on the terminal at the left suspension turret.
Install the support brace between the suspension turrets. Tighten the screws at the suspension turrets. Tighten to 50 Nm. Tighten the engine bracket screw. Tighten to 80 Nm.
Top up the coolant. Coolant volume approximately: 7 liters.
Connect the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
Fill with engine oil. Oil volume including filter: 5.8 liters.
Check the function
- Connect a VIDA station.
- Start the engine and run it until the thermostat opens.
- Read off any diagnostic trouble codes (DTCs)
- Check sealing.
- Check and if necessary adjust the oil and coolant levels
- Wipe clean.
Automatic transmissions: Check the transmission fluid level.