Replacing the gearbox: Preparation

Fig 1: Identifying Special Tool 999 5716 (Lifting Beam) And Special Tool 999 5460 (Lifting Hooks)

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(6 cylinder engines only) Installing the lifting tools. See Lifting tools Removing/Installing for 6 cylinder cars .

• (Diesel engines only) Remove the engine cover
• Install lifting beam 9995716 . Install lifting hooks 9995460
• Lift the engine to relieve the load on the engine pads.

Fig 2: Identifying Splash Guard Under Engine

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Remove 

• the front wheels
• the splash guard under the engine.

Fig 3: Identifying Air Duct Cover And Bolts

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• the air duct cover.

Fig 4: Identifying Screw For Cable Duct

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• the cable duct screw.

Fig 5: Identifying Oil Pipes And Steering Gear

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Remove 

• the oil pipes from the steering gear from the snap fasteners on the sub-frame
• the hose for the EVAP canister (Does not apply to diesel)
• any fuel line for the engine block heater and any engine block heater if mounted on the left hand side of the sub-frame
• any vacuum hose for the rear engine pad (applies to diesels), mounted on the left side of the sub-frame.

Fig 6: Identifying EVAP Canister Hose

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• the hose for the EVAP canister in the joint by pulling apart the hose. Route the hose under the anti-roll bar.

Fig 7: Identifying Exhaust Pipe Bracket Screws

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Remove 

• the mounting for the exhaust pipe on the bracket
• the screws holding the exhaust pipe bracket. Disconnect the brake pipe from the snap fasteners on the bracket
• the bracket.

Fig 8: Identifying Cable Harness And Connectors At Rear Edge Of Sub-Frame

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• Remove the cable harness from the rear edge of the sub-frame. Disconnect the connectors. (Applies only to cars with 6-cylinder engines)
• Remove the heated oxygen sensor (HO2S) bracket from the mounting.

Fig 9: Identifying Anti-Roll Bar Link

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• Remove the anti-roll bar links from the anti-roll bar. Counterhold using a Torx wrench so that the ball joint boot is not damaged.

Fig 10: Identifying Lower Torque Rod And Nuts

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• Remove both the nuts retaining the lower torque rod
• Remove the screw and bend up the bushing with the holder towards the torque rod.

Fig 11: Identifying Front Engine Pad Screw

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• Remove the front engine pad screw.

Fig 12: Identifying Fender Liner And Nuts

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• Slacken off the right lower front part of the fender liner. 
• Remove the plastic nuts on the fender liner
• Remove the splash guard
• Bend out the fender liner.

Fig 13: Identifying Vibration Damper

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• Remove the vibration damper. (Applies only to cars with 6-cylinder engines).

Fig 14: Identifying Right Hand Engine Mounting Screws

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• Remove both the right hand engine mounting screws.

Fig 15: Identifying Nuts And Screw For Steering Gear And Collision Protection

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• Remove the four nuts and the screw holding the steering gear to the sub-frame
• Remove the delivery line from the clips on the sub-frame
• Remove nut (A) holding the lower half of the collision protection. (Applies only to right-hand drive cars).

Fig 16: Identifying Ball Joint Nuts

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• Remove the nuts from the ball joints. Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Fig 1: Identifying Engine Cover

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• Disconnect the battery negative lead according to Battery, disconnecting .
• Remove the engine cover.

Fig 2: Identifying Engine Stabilizer Brace

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Remove 

• the screw for the torque rod mounting in the torque control arm on the engine.
• the screws at the suspension turrets.
• the torque rod.

Remove the three-way catalytic converter (TWC) according to Replacing the three-way catalytic converter (TWC) .

Fig 3: Identifying Collision Protection Over Oil Filter

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Applies only to right-hand drive: 

Remove the collision protection system over the oil filter.

Remove the oil drain.

Fig 4: Identifying Lower Oil Pipe

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Remove the lower oil pipe from the engine.

Lower the car.

Fig 5: Identifying Fuel Filter Nuts And ABS Connector

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Applies only to left-hand drive: 

Remove the ABS connector.

Remove the fuel filter from the right-hand suspension turret and place it to one side.

Fig 1: Identifying Exhaust Pipe Connection To Turbocharger

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Remove 

• the battery negative lead. First read Battery, disconnecting .
• the engine cover.
• the nuts for the exhaust pipe connection to the turbocharger (TC).
• the exhaust pipe. Move it to one side.

Fig 2: Identifying Splash Guard Under The Engine

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Raise the car and remove the splash guard from under the engine.

Fig 3: Identifying SIPS Member

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Remove 

• the member holding the front edge of the three-way catalytic converter (TWC).
• the brake pipe from the member.
• the mountings for the three-way catalytic converter (TWC) on the member.
  NOTE:

  Hang the heat deflector plate up with 2 screws.

Fig 1: Checking Manometer Values

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Connect the test equipment 

Connect manometer 5230  to the hose between the intake manifold and the charge air pressure sensor. Use a T piece (P/N 659 248-9  ), and a hose (P/N 1 257 639-3  ).

Route the manometer into the passenger compartment.