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Remove/install |
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Risk of death
caused by vehicle slipping or toppling off of the lifting platform. |
Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. |
AS00.00-Z-0010-01A |
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Notes on self-locking nuts and bolts |
All models |
AH00.00-N-0001-01A |
| 1 |
Position automatic transmission selector lever to "N" |
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Risk of explosion
caused by oxyhydrogen gas. Risk of poisoning and caustic burns
caused by swallowing battery acid. Risk of injury
caused by burns to skin and eyes from battery acid or when handling damaged leadacid batteries |
No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers. |
AS54.10-Z-0001-01A |
| 2 |
Disconnect battery ground cable |
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AR54.10-P-0003P |
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Notes on battery |
All models |
AH54.10-P-0001-01A |
| 3 |
Remove air filter housing (1) and both air intake pipes (2) |
 Installation:
Slightly moisten the rubber retainers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor (B2/5) in the air filter housing (1). |
AR09.10-P-1150AC |
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Lubricant |
*BR00.45-Z-1002-06A |
| 4 |
Remove suction-type fan |
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AR20.40-P-5000AC |
| 5 |
Remove poly-V-belt |
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AR13.22-P-1202PV |
| 6 |
Remove hot film mass air flow sensor (B2/5) |
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AR07.07-P-1454SV |
| 7 |
Remove purge line (9) |
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| 8 |
Detach vacuum line of brake booster at connection piece (10) of intake manifold |
To do this, press the two clamps (arrows) together and pull out the vacuum line. |
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| 9 |
Disconnect engine wiring harness |
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AR01.00-P-2410PV |
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Risk of explosion
caused by fuel igniting, risk of poisoning
caused by inhaling and swallowing fuel as well as risk of injury
to eyes and skin caused by contact with fuel. |
No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.
Wear protective clothing when handling fuel. |
AS47.00-Z-0001-01A |
| 10 |
Disconnect fuel line (8) at fuel distributor |
Release fuel pressure through service valve! Collect fuel. Seal connections. |
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*BA07.52-P-1001-01A |
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Pressure hose |
Fig 5 |
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Set of plugs |
Fig 6 |
| 11 |
Suction off oil from power steering expansion reservoir (7) of power steering pump (4) |
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Hand pump |
Fig 4 |
| 12 |
Detach power steering return line (6) at power steering expansion reservoir (7) of power steering pump (4) |
Seal connections! |
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Installation:
Check condition of hose clamp and power steering return line (6), replace if necessary. |
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*BA46.30-P-1004-01D |
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Set of plugs |
Fig 6 |
| 13 |
Detach power steering high pressure line (3) at power steering pump (4). |
Seal connections, in order to avoid foreign bodies getting in! |
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Installation:
Replace O-ring of pressure line. |
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*BA46.30-P-1003-01D |
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Set of plugs |
Fig 6 |
| 14 |
Drain and collect engine oil |
Installation:
Replace sealing ring of the oil drain screw. |
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*BA01.45-P-1003-01B |
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*BF18.00-P-1001-01H |
| 15 |
Remove complete exhaust system (24) as of flange connection of exhaust manifold |
On vehicles with engine damage it is necessary to inspect the exhaust system for swarf before installing it and to remove any swarf present, otherwise damage to the catalytic converter system may occur. |
AR49.10-P-7000AC |
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Installation:
Replace bolts. Check the rivet nuts in the exhaust manifold and replace them if required: ↓ |
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Replace rivet nuts in exhaust manifold. |
AR49.10-P-5531-01DA |
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*BA14.10-P-1002-01B |
| 16 |
Take off propeller shaft (17) at transmission |
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*BA41.10-P-1001-01A |
| 17 |
Detach selector lever rod (22) from transmission |
Installation:
Check fuse (21), replace if necessary. |
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| 18 |
Push propeller shaft (17) backward |
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| 19 |
Remove rear engine mount (18) at engine crossmember (25); at the same time, support automatic transmission with assembly lift |
Do not remove engine crossmember (25). Lower transmission on the engine crossmember (25). |
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*BA22.10-P-1002-01L |
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Transmission support |
*WE58.40-Z-1036-11A |
| 20 |
Take off refrigerant compressor (15) |
Attach refrigerant compressor (15) to bottom of engine compartment with lines connected. |
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*BA83.55-P-1001-01A |
| 21 |
Disconnect connector at refrigerant compressor (15). |
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| 22 |
Unscrew bolt of front engine mount (23) on the left and right at the front axle carrier |
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*BA22.10-P-1001-01L |
| 23 |
Detach top coolant line (16) at radiator |
Push back clamp until it locks in place, pull out top coolant line (16). |
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Installation:
Replace sealing rings of coolant lines. |
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| 24 |
Separate ATF line (13) from oil cooler |
Seal connections, in order to avoid foreign bodies getting in! Push back clamp until it locks in place, pull out oil line. |
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Installation:
Replace sealing rings of automatic oil line (13). |
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Set of plugs |
Fig 6 |
| 25 |
Detach residual heat pump coolant line (11) and expansion reservoir coolant line (12) at the water pump |
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| 26 |
Disconnect firewall coolant line (19) |
Pull out clamp from above. |
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| 27 |
Detach bottom coolant line (14) at radiator |
Push back clamp until it locks in place, pull out bottom coolant line (14). |
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Installation:
Replace sealing rings of coolant lines. |
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| 28 |
Attach guard plate for radiator / condenser |
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Guard plate for radiator / condenser |
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WF58.50-P-0110-01A |
| 29 |
Attach engine hoist to engine lifting eyes |
Engine hoist (self-locking) |
*WE58.40-Z-1012-11A |
| 30 |
Attach engine hoist to lifting eyes of engine |
Lower the support (car jack) below the transmission for this step. Tilt engine backward in stages with engine hoist and run out to the front with engine hoist. |
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| 31 |
Install in the reverse order |
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| 32 |
Bleed cooling system |
Warm up the engine to normal operating temperature and set the temperature control of heating to warm. |
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| 33 |
Inspect cooling system for leaks |
If the cylinder head gaskets are new, warm up engine first of all to operating temperature otherwise complete filling of the engine with coolant is not assured. |
AR20.00-P-1010P |
| 34 |
Check engine oil level |
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AR18.00-P-3035-01A |
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Risk of accident
caused by vehicle starting off by itself when engine is running. Risk of injury
caused by contusions and burns during starting procedure or when working near the running engine |
Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts. |
AS00.00-Z-0005-01A |
| 35 |
Check oil level in the automatic transmission. |
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AR27.00-P-0101P |
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Correct it if necessary. |
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| 36 |
Perform basic programming |
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AR00.19-P-0200P |
| 37 |
Read out fault memory and erase |
When the work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. |
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The stored faults can be caused by removed cables, assembly operations, test operations as well as by a simulation. |
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Connect STAR DIAGNOSIS and read out fault memory |
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AD00.00-P-2000-04A |
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Diagnosis system STAR DIAGNOSIS, Compact Passenger Car |
*WH58.30-Z-1048-13A |
| 38 |
Carry out function check |
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