Lifting out the engine and transmission: Preparation

WARNING: This page is about a different variant/trim than selected.

Fig 1: Identifying Under-Hood View

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Remove:

the negative battery cable. First read Battery, disconnecting .
the expansion tank cap.
Mark up and unplug connectors for heated oxygen sensors.
Loosen the retainer for the heated oxygen sensor wiring at the transmission.

Fig 2: Identifying Adapter Connected To Fuel Draining Unit

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Drain the fuel system. See Fuel system pressure release .

Part the fuel line and the EVAP-line's quick-coupling at the right rear attachment of the sub-frame.

NOTE: Protect the openings from dirt. Place the wiring to one side. Make sure that all cleanliness conditions for working with the fuel injection system are followed.

Fig 3: Identifying Radiator Drain Nipple

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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 left front wheel
tie rod end from the spindle.
the screw of the ball joint/wheel spindle.

Fig 4: Identifying Link Arm/Ball Joint And Wheel Spindle

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Detach the link arm/ball joint from the wheel spindle.

Pull down the link arm to release the ball joint.

Install the protective sleeve 9995562 on the ball joint.

If the ball joint is difficult to move in the wheel spindle, tap a screwdriver into the wheel spindle groove.

the screw for the bracket for the ABS-cable and brake pipes/hoses.
left drive shaft.
Pry tools 9995462 must be used to avoid damaging the lock ring.

the right front wheel.
tie rod end from the spindle.
the screw of the ball joint/wheel spindle.

NOTE: If the ball joint is difficult to move in the wheel spindle, tap a screwdriver into the wheel spindle groove.

Pull down the link arm to release the ball joint.

Install the protective sleeve 9995562 on the ball joint.

Fig 5: Identifying Sealing Plug 9995488 Installed In Hole Where Drive Shaft Was Positioned

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the screw for the bracket for the ABS-cable and brake pipe/hose.
the cap for the right drive shaft's intermediate bearing.
Pull loose the drive shaft and lay it carefully on the power steering pipes.
plastic nuts for the hatch in the right fender liner.
2 screws for the right engine mount.
First bend the right fender liner slightly so that it is out of the way.

NOTE: Install sealing plugs 9995488 in the holes where the drive shafts were positioned.

Fig 6: Identifying Lower Torque Rod Screw And Nut

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Remove the lower torque rod's screw and nut at the transmission.

Fig 7: Identifying Exhaust Pipe's Front Flange Seal Nuts And Front/Rear Engine Pad Screws

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Remove:

The SIPS member.
clamp for the rear seal.
nuts for exhaust pipe's front flange seal.
lift down the exhaust pipe.
the lower screws for front and rear engine pad.

Fig 8: Identifying Under-Hood View

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Lower the car to suitable working height and remove:

the battery: Battery, disconnecting .
the battery shelf.
the connector from the mass air flow sensor (HFM-unit).
the intake hose for the throttle body from the air filter cover.
the intake hose between the air cleaner housing and the front panel.
the solenoid valves from the air cleaner housing.
Place them over the engine.
the air cleaner assembly.

Remove:

the upper torque rod.
the braided ground cable between the engine and the cowl panel.
air preheating hose from the heat deflector plate over the manifold.
the heater hoses from the cowl panel

Fig 9: Identifying Protective Plate

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Remove the electric cooling fan.

Remove:

the air duct to the control module.
the connectors, relays and EVAP canister purge valve from the fan shroud.
Place the wiring to one side.
lift up the cooling fan and fan shroud with the relay holder's attachment.

Lift up the relay holder.

Remove the attachments for wiring to engine and transmission from the sub-frame.

Install protective plate 9995474 .

Fig 10: Identifying Lower Coolant Hose

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the lower coolant hose from the radiator.
cover over wiring to starter motor.
the ground cable on the transmission.
vacuum hose to brake booster from the intake pipe.
Place it to one side.

Fig 11: Identifying Clutch Cable

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Applies to cars with manual transmission.

Disconnect the clutch cable.
NOTE: Protect the clutch cable's free connections in a suitable way with drying paper. Make sure that all cleanliness conditions for working with the hydraulic system are followed.

Fig 12: Identifying Gear Selector Cables, Transmission Lever And Connector For Back Up (Reversing) Light Switch

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Remove:

the air cleaner housing bracket.

Applies to cars with manual transmissions

Mark up and remove the gear selector wires from their attachments on the transmission.
Remove the rubber-suspended section of the gear selector mounting.

Applies to cars with automatic transmissions

Detach the connector and detach the gear selector cable from the transmission.
Mark up the wire.
Loosen the two oil cooler hoses from the cooler using, e.g., lock ring pliers.

Fig 13: Identifying Power Steering Pump Pulley And Screws

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Remove:

the upper radiator hose from the thermostat housing.
expansion tank's hoses from the connections at the engine.
the auxiliaries belt
the 3 screws holding the power steering pump.
Loosen through the holes in the power steering pump's drive gear.

See Fig 13.

Disconnect the temperature sensor cable from the bracket on the power steering pump.

NOTE: Leave the power steering pump and tank in place for now.

Fig 14: Identifying A/C Compressor

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Unplug the connector of the AC compressor's electromagnetic clutch.

Remove the four screws holding the AC compressor in the engine.

Start with the lowest screws.

NOTE: Be careful so that the pipe does not break or crack when the upper screws are loosened.

Remove the AC-compressor and hang it up in the front cover plate.

Fig 15: Identifying Tool 9995722

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Remove the cover from the control module box.

NOTE: Do not touch the connector pins on the control module with your fingers. Components in the control module can be damaged by static electricity.

Insert tool 9995722 around the control module.

Move the tool's upper part backward to stop.

Pull up 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.