Removing the complete front axle with the engine and manual transmission (rear wheel drive)
WARNING:
Working on 12 V electrical system
.
Risk of short circuits! Risk of fire!
Risk of short circuits! Risk of fire!
- Make sure that there is no charger connected to the jump start terminal in the engine compartment.
- Detach battery ground lead from battery.
- For auxiliary batteries: Detach battery minus cables from all auxiliary batteries.
WARNING:
Car may slip off the vehicle hoist if the weight is distributed unevenly
.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Ensure there is a specific weight compensation on the car.
WARNING:
Car may slip off the vehicle hoist where components are supported
.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Secure the vehicle hoist against lowering and lifting.
- Make sure that the vehicle does not lift off the mounting plates on the vehicle lift.
CAUTION:
Heavy component
.
Heavy components can lead to injury or damage .
Heavy components can lead to injury or damage .
- Remove and install heavy components with the aid of another person/other persons.
NOTE:
RISK OF DAMAGE
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS) .
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults .
Damage to battery terminal, the safety battery terminal or the intelligent battery sensor (IBS) .
Damaged battery terminals can lead to malfunctions or vehicle electrical system faults .
- Detach battery terminal from battery pole by carefully shifting to and fro. Do not pry off using a tool.
NOTE:
RISK OF DAMAGE
Engine damage due to missing motor oil .
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train .
Engine damage due to missing motor oil .
Missing motor oil following replacement of the cylinder head or the engine can lead to damage on the valve train .
- After replacing the cylinder head or the engine, do not start the engine without observing the repair notes.
- It is imperative you observe the REPAIR NOTES FOR CYLINDER HEAD OR ENGINE REPLACEMENT .
NOTE:
TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.
Preliminary work
- Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
- Refer to SUCTIONING THE AIR CONDITIONING .
- Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
- Refer to REMOVING SUSPENSION STRUT BRACE .
- Refer to REMOVING THE ACOUSTIC COVER .
- Refer to REMOVING THE FRONT-END STRUT .
- Refer to REMOVING THE CLEAN AIR PIPE FOR CYLINDERS 1 TO 3 .
- Refer to REMOVING THE LEFT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
- Refer to REMOVING THE RIGHT INTAKE FILTER HOUSING (FRONT-END STRUT REMOVED) .
- Refer to REMOVING CLEAN AIR PIPE CYLINDERS 4-6 .
- Refer to REMOVING THE COVER FOR THE DME CONTROL UNIT .
- Refer to REMOVING THE DME CONTROL UNIT .
- Refer to REMOVING THE INTEGRATED SUPPLY MODULE (PDM) PARTIALLY .
- Refer to REMOVING THE CONTROL UNIT HOLDER .
- Refer to REMOVING SEALING FOR FRONT HOOD .
- Refer to REMOVING THE COVER FOR THE CENTER ENGINE COMPARTMENT .
- Refer to REMOVING UPPER CROSS CONNECTION .
- Refer to REMOVING THE REAR TOP CROSS CONNECTION .
- Refer to REMOVING THE FRONT SPOILER .
- Refer to REMOVING THE FRONT UNDERBODY PROTECTION .
- Refer to REMOVING THE LEFT AND RIGHT FRONT UNDERSHIELD .
- Refer to REMOVING THRUST FIELD .
- Refer to REMOVING THE RIGHT HAND FRONT BOTTOM SIDE COVER .
- Refer to REMOVING THE FRONT BOTTOM SIDE COVER .
- Refer to REMOVING FRONT LEFT OR RIGHT WHEEL .
- Refer to REMOVING THE COVER OF THE STEERING ASSEMBLY ON THE LEFT AND RIGHT .
- Refer to REMOVING THE FRONT SECTION OF THE FRONT WHEEL ARCH COVER ON THE LEFT AND RIGHT .
- Refer to REMOVING THE REAR SECTION OF THE WHEEL ARCH COVER ON THE FRONT LEFT AND RIGHT .
- Refer to PARTIALLY RELEASING THE ENGINE OIL COOLER .
- Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
- Refer to DRAINING THE COOLANT FOR THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to REMOVING THE CONNECTING SUPPORT FROM THE TUNNEL .
- Refer to REMOVING EXHAUST SYSTEM .
- Refer to REMOVING INTERMEDIATE PIPE .
- Refer to REMOVING THE TANK COVER .
- Refer to REMOVING THE LEFT THRUST FIELD .
- Refer to REMOVING TRANSMISSION CROSS-MEMBER .
- Refer to RELEASING THE WIRING HARNESS SECTION ON THE COVER OF THE TRANSMISSION CROSS MEMBER .
- Refer to REMOVING THE REAR HEAT SHIELD .
- Refer to REMOVING FRONT HEAT SHIELD .
- Refer to PARTIALLY LOOSENING THE PROP SHAFT .
- Refer to RELEASING THE GEARSHIFT RODS .
- Refer to RELEASING GROUND STRAP ON TRANSMISSION .
- Refer to PARTIALLY RELEASING THE CLUTCH SLAVE CYLINDER .
- Refer to REMOVING THE FAN COWL .
- Refer to REMOVING THE COOLANT EXPANSION TANK OF THE HIGH-TEMPERATURE COOLANT CIRCUIT .
- Refer to REMOVING THE COOLANT EXPANSION TANK FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
- Refer to DISCONNECTING THE COOLANT LINES .
- Refer to RELEASING THE REFRIGERANT LINES AT THE AIR CONDITIONING COMPRESSOR .
- Refer to RELEASING THE FUEL HOSE AND THE TANK VENTING LINE .
- Refer to RELEASING THE POSITIVE BATTERY CABLES FROM THE REMOTE POSITIVE TERMINAL .
- Refer to DETACHING THE WIRING HARNESS OF THE EPS FROM THE FRONT SUBFRAME .
- Refer to LOOSENING THE ANTI-ROLL BAR LINK ON THE LEFT AND RIGHT FROM THE ANTI-ROLL BAR .
- Refer to RELEASING UNIVERSAL JOINT ON STEERING GEAR .
- Refer to DETACHING THE LINE CONNECTION OF THE RIDE HEIGHT SENSOR .
- Refer to RELEASING THE WHEEL SPEED SENSOR AT THE LEFT FRONT AND RIGHT .
- Refer to RELEASING THE LEFT FRONT AND RIGHT BRAKE HOSE AT THE HOLDER .
- Refer to REMOVING THE LEFT FRONT AND RIGHT FRONT BRAKE VENTILATION DUCT .
- Refer to RELEASING THE FRONT LEFT AND RIGHT BRAKE CALIPERS .
- Refer to RELEASING THE SWIVEL BEARING AT THE LEFT FRONT AND RIGHT ON THE SPRING STRUT .
- Refer to ADDING WEIGHT COMPENSATIONS TO VEHICLE .
Prepared lifting table
WARNING:
Car may slip off the vehicle hoist if the weight is distributed unevenly
.
Danger! Immobilization period-threatening injuries!
Danger! Immobilization period-threatening injuries!
- Ensure there is a specific weight compensation on the car.
- Prepare special tool 2 184 136 .
- Have the set of special tools 2 305 379
ready.
Overview of the set of special tools 2 305 379 :
Number Description 10 Mount of swivel bearing with brake disc 20 Mounting element for adjustable mount 30 Adjustable stand 40 Distance pin 40 x 160 mm 50 Distance pin 40 x 110 mm 60 Distance pin 40 x 60 mm 70 Stand with U-profile 80 Round shaped mounting plate 100 mm - Prepare the special tool 2 184 136
.
Overview of the special tool 2 184 136:
Letter Description A Panel for engine with coordinates B Panel for manual transmission with coordinates - Position the adjustable mount (30) with the distance pin (60) for the front subframe on the panel (A) at the coordinates 6/1 and 6/8 .
- Position the mount (10) on the panel (A) at the coordinates 3/1 and 4/8 .
- Position the adjustable mount (30) with the distance pin (50) for the front subframe on the panel (A) at the coordinates 2/1 and 2/8 .
- Position the adjustable mount (30) with the round shaped mounting plate (80) for the transmission housing on the panel (B) at the coordinates 7/4 .
- Position the adjustable mount (30) with the mount with U-profile (70) for the transmission housing on the panel (B) at the coordinates 5/5 .
- Position the adjustable mount (30) with the distance pin (60) for the transmission housing on the panel (B) at the coordinates 3/4 .
- Release the screws (1) on the front subframe (2) at the left front .
- Release the screws (1) on the front subframe (2) at the right front .
- Release the screw (1) on the front subframe (2) at the left center with a commercially available tool (3) .
- Release the screw (1) on the front subframe (2) at the right center with a commercially available tool (3) .
- Position the lifting table with the distance pin (60) below the front subframe (1) at the right front .
- Screw the mounts to the lifting table.
- Position the lifting table with the distance pin (60) below the front subframe (1) at the left front .
- Screw the mounts to the lifting table.
- Position the lifting table with the distance pin (50) below the front subframe (1) at the left center .
- Screw the mounts to the lifting table.
- Position the lifting table with the distance pin (50) below the front subframe (1) at the right center .
- Screw the mounts to the lifting table.
- Position the lifting table with the distance dimension (60) below the manual transmission (1) at the rear .
- Screw the mounts to the lifting table.
- Position the lifting table with the mount with the U-profile (70) below the manual transmission (1) at the center .
- Screw the mounts to the lifting table.
- Position the lifting table with the round shaped mounting plate (80) below the manual transmission (1) at the front .
- Screw the mounts to the lifting table.
- Fasten the mount (1) on the brake disk at the left front with the lug bolts (2) .
- Attach adjustment screw (3) .
- Fasten the mount (1) on the brake disk at the right front with the lug bolts (2) .
- Attach adjustment screw (3) .
- Release the screws (1) and (2) on the front subframe (3) at the rear left .
- Release the screws (1) and (2) on the front subframe (3) at the right rear .
- Unscrew the screw (1) on the front subframe (2) at the right front .
- Unscrew the screw (1) on the front subframe (2) at the left front .
- Keep special tool 2 414 636 at hand.
- Spread the swivel bearing (1) with the special tool 2 414 636 in arrow direction .
- Detach the swivel bearing (1) from the spring strut (2) and set aside.
- Spread the swivel bearing (1) with the special tool 2 414 636 in arrow direction .
- Detach the swivel bearing (1) from the spring strut (2) and set aside.
WARNING:
Heavy component
.
Heavy components can lead to injury or damage .
Heavy components can lead to injury or damage .
- Remove and install heavy components with the aid of another person/other persons.
- Lower the lifting table (1) slowly in arrow direction and pay attention to the free movement of all components.
- Mark (arrows) the position of the lifting table (1)
on the workshop floor.
The marks (arrows) facilitate installation.
- Mark (arrows) the position of the lifting table (1)
on the workshop floor.
The marks (arrows) facilitate installation.