Engine/transmission, removing/installing: Removal: Preparation

Fig 1: Engine Compartment Components

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Remove: 

• the battery negative cable. First read 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 .

Drain the fuel system, applies only to B5xx4S6  . See Fuel system pressure release .

Separate the fuel line and EVAP line quick-release connector at the right rear subframe mounting. See also Fuel system, quick-release connectors .

Drain the fuel system according to Draining the fuel system

Fig 2: Identifying Bottom View Of Engine With Splash Guard Removed

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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 right, replacing 
• the left-hand drive shaft. See Drive shaft left, replacing 
• the screw for the lower torque rod in the transmission.

• the lower screws of the front and rear engine mountings.

Fig 3: Heated Oxygen Sensor Connectors

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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.

Fig 4: Exhaust At Manifold

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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.

Fig 5: Air Cleaner Housing

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• 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.

Fig 6: Engine Compartment Components - Front

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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 9995474 .

Applies to cars with manual transmissions 

Fig 7: Identifying Mechanical Transmission Cables

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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 

Fig 8: Automatic Transmission Cables

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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.

Fig 9: Identifying Power Steering Pump And Screws

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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.

Fig 10: AC Compressor

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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.

Remove the compressor and hang it up on the front cover plate.

Fig 11: Engine Control Module

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Remove the cover from the control module box.

Insert tool 9995722 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.