the cable to the battery negative terminal. First read Note when disconnecting / connecting the battery lead.
air cleaner (ACL) housing assembly including intake manifold. Lift up the servo reservoir and place on top of engine.
Note: Ensure that the fluid does not run out of the ventilation hole in the filler cap.
the engine wiring ground lead.
the cover from the control module box.
control modules. Use mounting bracket 999 5722.
the control module box intermediate section.
Pry out connector plate from control module box lower section and pull out engine and transmission wiring connectors from the plate.
Place engine and transmission wiring on top of engine.
the upper torque rod screw from the engine.
the cross stay from the suspension turret.
the engine wiring from the positive terminal block at the left suspension turret.
Note: Be careful that the cable does not crack or break.
Remove expansion tank cover.
Place a container under the radiator drain cock.
Drain the coolant: Avoid skin contact.
Close cock.
Disconnect the hose to the radiator from the expansion tank.
Lift up tank and place on top of engine.
The canister purge (CP) valve from the mounting on the fan shroud.
the canister purge (CP) valve connector.
the intake hose between the turbo pipe and the charge air cooler (CAC) . (Applies only to B6xx4T). Disconnect intake manifold from charge air cooler (CAC).
the connector from the pressure switch on the dryer bottle.
the engine cooling fan (FC) connector.
wiring from terminal block. Place it over the engine. Release the fan shroud from the wiring.
Relieve the load from the auxiliaries belt tensioner and remove the belt from the power steering pump.
Disconnect air conditioning (A/C) compressor magnetic clutch connector.
Remove the four screws retaining the air conditioning (A/C) compressor in engine. Start with the lowest screws.
Note: Be careful that the pipe does not break or crack when the upper screws are loosened.
Remove air conditioning (A/C) compressor and tie it up in the front cover plate.
Remove the panel under the dashboard on the driver's side.
Turn steering wheel to gain best possible access to the steering shaft nut.
Remove ignition key so that steering wheel lock is activated.
Slacken off joint from the lower steering shaft. Cut off tie straps and remove the bushing from the boot.
Note: Do not change the position of the front wheels until a measurement has been taken to, for example, the sub-frame. Note the measurement. This is done to prevent damage to the SRS system's contact reel.
Remove
front wheels.
front splash guard.
the splash guard under the engine. Disconnect anti-roll bar links from anti-roll bar.
Note: Clean and spray the exposed threads with rustproofing agent before beginning removal.
Remove (on both sides)
tie rod ends from the steering ann. Use puller 999 5259.
the brake pipe bracket from the mounting in the wheel arch.
the ABS sensor cable from the spring strut.
the ABS sensor hang up the sensor.
the screw holding the drive shaft to the hub.
the nut for the ball joint/link arm.
Note: Counterhold with Torx 40 so that the ball joint boot does not turn when the nut is removed.
Disconnect brake pipe from clips on the front cross member.
Position a container under the engine drain cock. Drain the engine coolant.
Transfer container to radiator draining tap and drain off remaining coolant.
Close the nipples.
Collect any oil and water spillage.
Drain fuel line.
Disconnect the fuel line quick-release connector at the engine.
Note: Protect openings against dirt.
Place cable to one side.
Separate EVAP line at quick-release connector.
Lowering the engine/transmission unit
Position a lifting table under the sub-frame. Position the table against the sub-frame.
Note: ensure that the lifting table is centered under the sub-frame for optimal weight distribution.
Remove
the sub-frame brackets screws.
sub-frame screws. Lower the engine/transmission approximately 15 cm (5.91 inch) so that the drive shafts describe a horizontal line between the hub and transmission.
Note: Take great care that no hoses, wiring or anything else catch in the engine/transmission unit when it is lowered.
Unhook the control arms from the ball joint pinion.
Remove the drive shafts from the hub.
Note: Do not pull the drive shafts if they do not have axial locks.
Let the drive shafts rest against the control arms.
Continue lowering the engine/transmission unit.
