Engine - Removal, Replacement and Installation: Other Volvo S60 I

Crankshaft seal rear, replacing

Special tools

9995112

9997174

9991801

9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Scheme 34

Remove the gearbox

1. manual transmissions . For gasoline M56 and M58 2001- see «Transmission, installation»(ref-415257-S17236064702011081500000) . For D5244 M56 2001- see «Transmission, installing»(ref-445706-S03253020912012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing»(ref-415257-S05144685332011081500000) . .
2. automatic transmissions . See For gasoline AW55-50 and AW50AWD 2001- see «Transmission, removing»(ref-415257-S25642676622011081500000) For D5244 AW55-50 2001- see «Transmission, removing»(ref-445706-S19998490872012010600000) . .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Scheme 35

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Scheme 36

Note. To clean the crankshaft, use cloth 9511024.

Installing the sealing ring

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 37

Thread the seal onto the bevelled part of the inner section of 9997174 with the felt side of the seal outward.

Screw the drift onto the crankshaft (2 screws) of the flywheel.

Pull in the seal with the outer part of the drift, 9997174 , using the screw in the center of the tool. The seal is in place when the outer drift bottoms against the inner drift. Remove tool 9997174 . Scrap the old flywheel screws.

Scheme 38

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
3. Then angle-tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Gearbox, installing

Install the gearbox

1. manual transmissions For gasoline M56 and M58 2001- see «Transmission, installation»(ref-415257-S17236064702011081500000) . For D5244 M56 2001- see «Transmission, installing»(ref-445706-S03253020912012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing»(ref-415257-S05144685332011081500000) .
2. automatic transmissions For gasoline AW55-50 2001- see «Transmission, installation»(ref-415257-S06587987422011081500000) For D5244 AW55-50 2001- see «Transmission, installing»(ref-445703-S29676301232012010600000) . For TF-80SC D5244TX 2006-, see .

Checking the engine

Test drive the car to check the function of the engine and the gearbox.

Crankshaft seal, front, replacing

Replace the front crankshaft seal. See Oil pump / crankshaft seal, front, replacing .

Replacing the carrier plate

Special tools

9995112

9995678

Preparatory work

Remove the transmission according to Transmission, removing .

Removing the carrier plate

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Scheme 39

Block the carrier plate using gear sector 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector «9995112»(ref-403953-S01318438012011061000000) .

Scheme 40

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Scheme 41

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use tool 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) , distributed as illustrated
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate gear sector 9995112 against the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten crosswise. Tighten to 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten the screws. Tighten to 45 Nm . Then angle-tighten all 10 screws crosswise. Tighten to 50°.

Install the engine speed (RPM) sensor with the bracket. Tighten to 10 Nm .

Finishing

Install the transmission according to Transmission, installation .

Special tools

9995112

9995651

9991801

9995678

9995676

9512050

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing the flywheel and carrier plate

Remove the gearbox

1. manual transmissions For gasoline M56 and M58 2001- see «Transmission, removing»(ref-415257-S40455021012011081500000) . For D5244 M56 2001- see «Gearbox, removing»(ref-445710-S39964431742012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, removing»(ref-415257-S33778855242011081500000) .
2. automatic transmissions For gasoline AW55-50 and AW50AWD 2001- see «Transmission, removing»(ref-415257-S25642676622011081500000) For D5244 AW55-50 2001- see «Transmission, removing»(ref-445706-S19998490872012010600000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Removing the seal

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Scheme 42

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Installing flywheel and carrier plate

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. Then angle tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Install the gearbox

1. manual transmissions For gasoline M56 and M58 2001- see «Transmission, installation»(ref-415257-S17236064702011081500000) . For D5244 M56 2001- see «Transmission, installing»(ref-445706-S03253020912012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing»(ref-415257-S05144685332011081500000) .
2. automatic transmissions For gasoline AW55-50 2001- see «Transmission, installation»(ref-415257-S06587987422011081500000) For D5244 AW55-50 2001- see «Transmission, installing»(ref-445703-S29676301232012010600000) . For TF-80SC D5244TX 2006-, see

Test drive the car to check the function of the engine and the gearbox.

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

Flywheel

Special tools

9995112

9995678

Remove

1. transaxle «Transmission, removing»(ref-415257-S40455021012011081500000)
2. clutch «Clutch disc and pressure plate»(ref-415511-S07198701022011081500000)

Removing the flywheel

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Slacken off all the screws for the flywheel. Remove all the screws except for one.

Remove the gear sector 9995112 .

Detach the flywheel from the crankshaft. Remove the remaining screw.

Remove the flywheel.

Checking the crankshaft seal

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Installing the flywheel

Note. Ensure that the mating surfaces on the crankshaft and flywheel are completely clean.

Use tool 9995678 , consisting of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated
2. the flywheel.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.

Note. Only applies to cars with dual mass flywheels: There is a marking in the form of a shallow hole (see the arrow). The marking indicates the direction to the guide hole on the flywheel.

Fit the gear sector 9995112 against the flywheel.

Tighten in the flywheel against the crankshaft, alternate between nuts when tightening. Use the 3 nuts that belong to tool 9995678 .

Install 7 new screws. Tighten crosswise with 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws for the flywheel and tighten with 45 Nm . Then angle-tighten all 10 screws crosswise 65°.

Install the impulse sensor with bracket. Tighten with 10 Nm .

Install

1. clutch. «Clutch disc and pressure plate»(ref-415511-S07198701022011081500000)
2. transmission. «Transmission, installation»(ref-415257-S17236064702011081500000)

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

Special tools

9995112

9995651

9991801

9995678

9997174

9512050

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Remove the gearbox

1. manual transmissions . See For gasoline M56 and M58 2001- see «Transmission, removing»(ref-415257-S40455021012011081500000) . For D5244 M56 2001- see «Gearbox, removing»(ref-445710-S39964431742012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, removing»(ref-415257-S33778855242011081500000) .
2. automatic transmissions . For gasoline AW55-50 and AW50AWD 2001- see «Transmission, removing»(ref-415257-S25642676622011081500000) For D5244 AW55-50 2001- see «Transmission, removing»(ref-445706-S19998490872012010600000) .

Remove the flywheel / carrier plate. Use gear sector 9995112 as a counterhold when slackening off the screws.

Note. Do not damage the mating surfaces of the crankshaft and cylinder block

Remove the old seal using extractor 9995651 .

Clean around the crankshaft flange at the front and rear. Remove any thread sealant residue from the screw holes.

If necessary wash off the oil on the rear cylinder block surface and the gearbox clutch housing. Blow clean using compressed air.

Note. To clean the crankshaft, use cloth 9511024.

Lubricate the sealing ring mating surface against the cylinder block and the lips of the seal.

Thread the seal onto the beveled section of the inner section of tool 9997174 with the felt side of the seal outwards. Install the drift on the crankshaft, 2 x screws, for the flywheel. Pull in the seal using the outer section of the drift: 9997174 using the screw in the center of the tool. The seal is in position when the outer drift bottoms out against the inner drift. Remove the tool: 9997174 . Discard the old screws for the flywheel.

Install

1. the flywheel and carrier plate
2. the 3 studs «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated. Turn the short thread length towards the crankshaft.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel / carrier plate. The position of the guide hole is marked.

1. Align gear sector: «9995112»(ref-403953-S01318438012011061000000) .
2. Pull the flywheel / carrier plate towards the crankshaft using the 3 nuts on special tool «9995678»(ref-403953-S14391401472011061000000) . The turned section of the nut must be turned towards the flywheel / carrier plate.

1. Install the other screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
2. Replace the 3 special screws with new standard screws. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
3. Then angle tighten all 10 screws crosswise. Use «9512050»(ref-403953-S36645634772011061000000) . Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
4. Ensure that the flywheel sensor and bracket are installed. Install the clutch driven plate and clutch.

Install the gearbox

Install the gearbox

1. manual transmissions For gasoline M56 and M58 2001- see «Transmission, installation»(ref-415257-S17236064702011081500000) . For D5244 M56 2001- see «Transmission, installing»(ref-445706-S03253020912012010600000) . For gasoline M66AWD 2004- and M66 2005- see «Transmission, installing»(ref-415257-S05144685332011081500000) .
2. automatic transmissions For gasoline AW55-50 2001- see «Transmission, installation»(ref-415257-S06587987422011081500000) For D5244 AW55-50 2001- see «Transmission, installing»(ref-445703-S29676301232012010600000) . For TF-80SC D5244TX 2006-, see

Test drive the car to check the function of the engine and the gearbox.

Replace the front crankshaft seal. See Oil pump / crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal, front, replacing

See Flywheel

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

See Crankshaft seal rear, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

Flywheel, replacing

Special tools

9995112

9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing transmission and clutch

To remove the transmission, see: Transmission, removing .

To remove the clutch: Pressure plate/clutch driven plate, replacing .

Note. The illustrations display a dual mass flywheel, but the method is the same for the single mass flywheels.

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Slacken off all the screws for the flywheel. Remove all the screws except for one.

Remove: 9995112 .

Detach the flywheel from the crankshaft. Remove the remaining screw.

Remove the flywheel.

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Note. Ensure that the mating surfaces on the crankshaft and flywheel are completely clean.

Use: 9995678 , which consists of 3 studs with nuts.

Install

1. 3 studs belonging to «9995678»(ref-403953-S14391401472011061000000) , distributed as illustrated
2. the flywheel.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.

Note. Only applies to cars with dual mass flywheels. There is a marking in the form of a shallow hole (see the arrow). The marking indicates the direction to the guide hole on the flywheel.

Locate: 9995112 against the flywheel.

Alternately tighten the nuts on the flywheel to the crankshaft. Use the three nuts which belong to 9995678 .

Install 7 new screws. Tighten. See

Remove the 3 nuts and studs.

Install the remaining 3 new screws for the flywheel. Tighten. See.

Install the engine speed (RPM) sensor with the bracket. Tighten.

To install the clutch, see: Pressure plate/clutch driven plate, replacing .

To install the transmission, see: Transmission, installing .

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Replacing the carrier plate

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

Special tools

9995112

9995678

Replacing flywheel

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Preparations

Removing the transmission: see Transmission, removing .

To remove the clutch: for gasoline see Pressure plate/clutch driven plate, replacing .

Note. The illustrations display a dual mass flywheel, but the method is the same for cars with a massive flywheel.

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Slacken off all the screws for the flywheel. Remove all the screws except for one.

Remove the gear sector 9995112 .

Detach the flywheel from the crankshaft. Remove the remaining screw.

Remove the flywheel.

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Note. Check that the contact surfaces on the crankshaft and flywheel are completely clean.

Use tool 9995678 , consisting of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated
2. the flywheel.

Note. Check that the guide pin on the crankshaft is positioned directly opposite the hole in the flywheel.

Note. Only applies to engines with dual mass flywheels: There is a marking in the form of a shallow hole (see arrow). The marking indicates the direction to the guide hole on the flywheel.

Fit the gear sector 9995112 against the flywheel.

Tighten in the flywheel against the crankshaft, alternate between nuts when tightening. Use the 3 nuts that belong to tool 9995678 .

Install 7 new screws. Tighten crosswise with 45 Nm .

Remove the 3 nuts and studs.

Install the remaining 3 new screws for the flywheel and tighten with 45 Nm . Then angle-tighten all 10 screws crosswise 65°.

Install the impulse sensor with bracket. Tighten with 10 Nm .

To install the clutch: for gasoline see Pressure plate/clutch driven plate, replacing .

To install the gearbox: for gasoline see Transmission, installation .

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Flywheel

Carrier plate, replacing

Special tools

9995112

9995678

Remove transmission AW55-50. See TRANSMISSION, REMOVING .

Remove transmission AW50AWD. See Transmission, removing .

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Block the carrier plate using gear sector 9995112 .

Remove

1. all screws
2. the carrier plate
3. gear sector «9995112»(ref-403953-S01318438012011061000000) .

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Note. For tightening torques, see Tightening torque .

Installing the carrier plate

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use tool 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) , distributed as illustrated
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Locate gear sector 9995112 against the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten. See Summary of specific components and tightening torques .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten. See Summary of specific components and tightening torques .

Install the engine speed (RPM) sensor with the bracket. Tighten.

Install transmission AW55-50. See TRANSMISSION, INSTALLING (B5204T5, AW55-50/51SN; 2004-2007) .

Install transmission AW50AWD. See TRANSMISSION, INSTALLING (AW50AWD) .

Removing the transmission

Special tools

9985972

9995185

9995460

9995463

9995562

9995681

9995716

9995972

9997070

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. Before replacing the transmission, fill in Diagnostics/check list and enclose in the returns box.

Disconnecting the battery lead

Disconnect the battery lead. See Battery, disconnecting .

Removing engine compartment components

Scheme 43

Remove

1. the engine stabilizer brace between the suspension turrets and the engine
2. the air cleaner (ACL) housing assembly with the intake pipe.

Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing.

Pull the air cleaner (ACL) housing out of its mountings.

Removing the charge air pipe

Scheme 44

Detach the charge air pipe from the charge air cooler (CAC).

Carefully heat around the pipe at the charge air cooler (CAC). Use a hot air gun. Loosen and remove the pipe.

Removing components from the transmission

Scheme 45

Remove

1. the gear selector cable. Use jimmy tool «9997077»(ref-403953-S08742937252011061000000) to detach the ball joint for the cable from the lever
2. the cable mounting from the transmission
3. the oil line from the transmission. Plug the line and the connection on the transmission cover
4. unhook the mounting with the connector for the transmission from the bracket. Separate all the connectors.

Removing the transmission mounting screws

Scheme 46

Remove the bracket with the connectors for the heated oxygen sensors (HO2S) and the clamp for the cable harness from the transmission.

Remove

1. the screws for the clamp securing the cable harness at the rear edge of the engine
2. the nut for the bracket for the cable harness and the engine coolant hose
3. the 3 screws for the transmission and engine and the 2 screws for the starter motor. Tie up the cable harness.

Removing the coolant hose from the passenger compartment heater

Scheme 47

Clamp the hoses with hose clips.

Place some paper under the inner hose connection to collect any spilled coolant.

Turn the quick-release connector (the inner of the two hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.

Note. Tie the hose up to the engine so that it does not fall down and trap the hose connector between the firewall during installation.

Installing the lifting beams and lifting hooks on the engine lifting lugs

Scheme 48

Note. The front lifting beam must be equipped with fixture kit 9997070 as illustrated.

Position lifting beam 9995716 on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.

Connect the lifting hooks 9995460 on the engine lifting lugs.

On the right-hand side of the engine, the hook must have a clearance of 10 mm . Also use lifting lug 9995185 on the left-hand side of the engine. Tighten to light contact on the left hand side.

Raise the car

Scheme 49

Remove

1. the front splash guard. See «Sub-frame front, replacing»(ref-445738-S28904871842012010600000)
2. the splash guard under the engine.

Scheme 50

Remove the screw for the cable duct. Unhook the cable duct from the sub-frame.

For cars with fuel powered parking heaters

Remove the 2 screws for the heater.

Unhook the heater from the mounting. Leaving it hanging in its upper mounting.

Detach the fuel line for the heater from the holders on the sub-frame.

Scheme 51

Remove

1. the clamp for the heated oxygen sensor (HO2S) cable and the screws for the front member
2. the brake pipe from the holders on the member
3. the rear member. Remove one screw and slacken off the other.

Turn the member to the side so that the exhaust pipe is exposed.

Scheme 52

Remove rubber mounting for the exhaust system from the brackets.

Scheme 53

Remove

1. the screw for the front engine pad
2. the screws for the torque rod
3. the screw and nuts for the steering gear.

Scheme 54

Remove

1. the screw for the clamp for the power steering line at the front edge of the top of the sub-frame
2. the screw for the clamp for the power steering line on the right-hand side at the rear edge of the frame.

Unhook the servo and the evaporator lines from the holders on the right-hand side of the sub-frame.

Scheme 55

Remove

1. the soundproofing over the drive shaft (applies to certain versions)
2. the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
3. the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning
4. the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.

Scheme 56

Use tool 9997062 . Install cap nut 9997062 for the ball joint pinion. Tighten the nut to the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.

Position puller 9997062 on the control arm and detach the ball joint from the control arm.

Remove the tools.

Scheme 57

Slacken off the 2 nuts for the fender liner and the support plate on both sides so that the fender liner can be folded out.

Scheme 58

Remove the screws for the sub-frame support plates in the body (both sides).

Position mobile jack 9985972 with universal plate 9995972 , so that the plate is in light contact under the right-hand side of the sub-frame.

Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.

Remove the jack.

Unhook the control arm from the ball joint. Install protective sleeve 9995562 . Hold the sleeve in place using the nut for the ball joint.

Work out the spring strut. Detach the drive shaft from the wheel hub. Do not damage the boot. Hold the spring strut to one side using a retaining strap for more space when removing the drive shaft.

Scheme 59

Remove

1. the support bearing cap for the drive shaft
2. the drive shaft by pulling it straight out of the transmission.

Scheme 60

Note. Applies only to right-hand drive cars.

Remove the 2 screws for the collision protection system.

Leave the collision protection system in place on the steering gear.

Scheme 61

Note. For cars with fuel powered parking heaters: mark up the position of the mounting in relation to the sub-frame.

Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.

Note. Ensure the following when lowering the sub-frame: that the steering gear screws release from the sub-frame that the brake pipe does not catch in the bracket for the exhaust pipe mounting that the ball joint pinion releases from the control arm.

Remove the mobile jack and let the frame hang loose.

Scheme 62

Work out the spring strut. Detach the drive shaft from the wheel hub. Hold the spring strut to one side using a retaining strap to obtain more space when removing the transmission.

Scheme 63

Remove the drive shaft from the transmission. Use jimmy bar 9995681 .

Scheme 64

Remove

1. the screw for the engine pad/steering gear
2. the 3 screws
3. the mounting and the engine pad.

Scheme 65

Hang up the steering gear in a tie strap. Use the hole in the body.

Scheme 66

Remove the 6 screws for the torque converter. Turn the engine with a ratchet and socket. Fold out the right-hand fender liner so that the crankshaft nut can be accessed.

Use a Torx TX50 socket on the torque converter screws.

Scheme 67

Position a container under the pipe terminal.

Remove

1. the 2 screws holding the pipe. Disconnect the pipe from the transmission. Install sealing plugs in the pipe and transmission. Carefully fold the hose out of the way
2. the ground lead from the transmission.

Scheme 68

Lower the engine and transmission on the left-hand side using the hook.

Check that no hoses or cables are being stretched or trapped when the engine is lowered.

Lower the engine so that 90-100 mm of the free threads on the lifting hook can be seen.

Raise the car.

Scheme 69

Raise the car.

Install fixture 9995463 on fixture 9995972 . Use the fixture and plate together with mobile jack 9985972 . Align support plate 999 5463-2 against the fixture and the transmission.

Note. The support plate is installed on the inside of the fixture mounting lug (see the illustration). Tighten the fixture with the two torque rod screws. Apply the mobile jack lightly against the transmission.

Scheme 70

Remove the remaining 7 screws for the transmission and engine.

Scheme 71

Ensure that the transmission is taken straight out in relation to the engine.

Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft.

Press a screwdriver through one of the screw holes in the carrier plate.

Note. Do not pry toward the carrier plate rim for the flywheel sensor.

Note. Lower the transmission slightly when it is being removed so that it will pass the side member.

Remove the transmission.

Transmission, installing

Special tools

9512050

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. For tightening torques, see Tightening torque .

Installing the transmission

Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing .

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.

Installing and tightening the screws for the transmission

Install all 7 x M10 screws securing the transmission to the engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Then tighten the screws crosswise.

Remove the fixture from the transmission.

Installing the torque converter screws

Note. Use new screws.

Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.

Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. See Summary of tightening torques for specific components . Use a Torx socket TX50.

Note. Remove the socket wrench from the crankshaft.

Lifting the engine and transmission

Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.

Note. Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.

Raise the car.

Installing the rear engine mounting

Remove the tie strap temporarily holding the steering gear.

Install

1. the rear engine mounting on the transmission
2. the 3 x M10 screws for the engine mounting. Tighten
3. the screw for the steering gear and engine pad loosely.

Check and if necessary align the bearing for the steering shaft in the boot when installing the steering gear. Also see Checking the boot for the steering shaft/firewall .

Installing the lower oil pipe on the transmission

Use a new O-ring.

Install

1. the oil pipe and dip stick pipe. Use both the screws. Tighten. See «Summary of tightening torques for specific components»(ref-415455-S06042927612011081500000)
2. a tie strap for the cable harness for the oil pipe
3. the ground lead to the engine.

Installing the left drive shaft on the transmission and the wheel spindle

Scheme 72

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Installing the subframe on the bodywork

Note. Use new screws. Lubricate the screw threads.

Lift the subframe until it is about 150 mm from the side member.

Secure the power steering pipe at the front edge of the upper side of the subframe. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily. Check the steering gear bearing in the boot at the firewall.

Note. Ensure the following when lifting the subframe

1. ensure that the steering gear screws align in the frame
2. ensure that the brake pipe passes the bracket for the exhaust pipe
3. ensure that the ball joint pinion for the spring strut aligns in the control arm.

Install

1. the new screws and the support bracket at the rear edge
2. the screws for the bracket loosely.

Applies only to cars with fuel driven parking heaters

Align the washer with the mounting lug following the marking on the subframe.

Tighten the subframe screws. Tighten to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft on the transmission, wheel spindle and control arm

Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Scheme 73

Position the mobile jack lightly applied under the right side of the subframe.

Install

1. new screws in the subframe NOTE: Lubricate the screw threads.
2. the screws loosely at the rear edge of the support plate.

Tighten the subframe screws. Tighten to light contact.

Remove the mobile jack.

Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.

Tighten acc. to: Tightening torque . First tighten the screws on the sub-frame's left side, then on the right.

Tighten the screws for the brackets M10.

Installing components on the engine and subframe

Scheme 74

Install

1. 4 new M10 lock nuts for the steering gear and 1 M10 screw. Tighten
2. 1 M10 screw for the front engine pad. Tighten.

Tighten the M10 screw for the rear engine pad.

Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Summary of tightening torques for specific components .

Installing the collision protection system over the steering gear

Applies only to right-hand drive cars

Install the 2 screws. Tighten.

Installing the servo pipe in the holders

Press the power steering pipe and the evaporator pipe into the holders on the subframe. (If there is a parking heater, also press its fuel line and the evaporator cable into place)

Install and tighten the clamps for the power steering pipe at the rear of the frame. Tighten the clamp and the clamp for the power steering line at the front edge of the top of the subframe.

Installing the front mounting for the exhaust pipe

Install the rubber mountings for the exhaust system on the brackets on the subframe.

Installing the cross members on the body

Install

1. the M8 screws for the front member
2. the brake pipe in the holders on the member
3. the M8 screws for the rear member
4. the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.

Installing front suspension components

HINT: Applies when installing front suspension components on both sides.

Install

1. a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
2. the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See «Summary of tightening torques for specific components»(ref-415459-S09555248762011081500000) . Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See «Summary of tightening torques for specific components»(ref-415455-S06042927612011081500000)
3. the soundproofing over the drive shaft (applies to certain versions).

Installing components for the fender liner

Install the support plate and the nuts on both sides.

Installing the cable duct

Install

1. the cable duct on the subframe
2. any parking or additional heaters in the mounting in the subframe and the fuel line in the mountings.

Installing the front splash guard

Install

1. the splash guard under the engine
2. the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Removing the lifting beams

Lower the car.

Remove the lifting beams and hooks from the engine.

Installing the coolant hose

Install the connector securing the engine coolant hose to the heater.

Remove the hose clips.

Installing the remaining screws for the transmission and starter motor

Install

1. the 3 x M10 screws for the transmission and engine. Tighten
2. the 2 x M10 screws for the starter motor. Tighten. See «Summary of tightening torques for specific components»(ref-415306-S20035207612011081500000)
3. the bracket for the engine coolant hose and cable harness
4. the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
5. the clamp for the cable harness at the rear edge of the engine.

Installing the gear selector cable and oil pipe

Scheme 75

Install

1. the ground lead and mounting on the subframe
2. the oil pipe on the transmission
3. the gear selector cable and bracket. Use 2 x M8 screws. Tighten.

Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.

Note. Check that the transmission bleed hose / valve is not trapped. There is a risk of overpressure in the transmission.

Installing service clips

Scheme 76

Note. The automatic transmission has a gear selector cable while the manual transmission has two gear selector cables.

Ensure that the gear selector cable is engaged before fitting the blue clip. Press the clip into position as illustrated.

Scheme 77

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components

Install

1. the charge air pipe to the charge air cooler (CAC)
2. the air cleaner (ACL) housing assembly with the intake manifold and connections
3. hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
4. the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
5. 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
6. the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.

Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.

Also see Transmission replacement, post-checking .

Checking the boot for the steering shaft/firewall

Scheme 78

Check that the bearing in the boot is in position.

If it has become detached apply a little grease to the edge of the boot (around the hole). Press the bearing back down into the boot.

Check that the boot is correctly positioned against the firewall and that the snap ring is correctly positioned. Adjust if necessary.

Note. It is essential that the above checks are carried out. Otherwise there may be noise from the transmission/engine and road noise in the passenger compartment.

Installing the battery lead

Connect the battery lead.

First read Battery, disconnecting .

Finishing

Carry out checks after working on the transmission. See Transmission replacement, post-checking .

Special tools

9512050

9997057

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. For tightening torques, see: Tightening torque .

Installing the transmission

Before installing the transmission it is very important that the checks and cleaning have been carried out. See Transmission, preparations before installing .

Adjust height and angle with the mobile jack and the transmission fixture.

Locate the transmission on the engine.

Ensure that the transmission goes straight in, in relation to the engine, and that the guide sleeves and guide pin for the starter motor align in the guide holes on the transmission.

Installing and tightening the screws for the transmission

Install all 7 x M10 screws securing the transmission to the engine.

First tighten alternately and crosswise to light contact.

At the same time, check that the whole of the transmission is in contact with the engine.

Then tighten the screws crosswise.

Remove the fixture from the transmission.

Installing the torque converter screws

Note. Use new screws.

Align the torque converter against the carrier plate. Do this by turning the engine with the nut for the crankshaft pulley and turning the torque converter.

Install all 6 screws loosely. Tighten the screws. Tighten until the heads are almost in contact with the carrier plate. Tighten. See Summary of tightening torques for specific components . Use a Torx socket TX50.

Note. Remove the socket wrench from the crankshaft.

Lifting the engine and transmission

Lift the engine to slightly above the horizontal position to provide better access to the rear engine mounting and engine pad.

Note. Check that the connection on the hose for the heater is not trapped between the engine and firewall when the engine is lifted.

Raise the car.

Installing the rear engine mounting

Install

1. the rear engine mounting on the transmission
2. the 3 x M10 screws for the engine mounting. Tighten.

Installing the bevel gear

Scheme 79

Note. Before installing the bevel gear, lubricate the spline joint between the transmission and the bevel gear using grease. See: Splines greasing .

Ensure that the mating surfaces on the transmission and bevel gear are clean and not damaged.

Install the bevel gear. Use new screws. Tighten the screws alternately to light contact. Tightening torque .

Installing the lower oil pipe on the transmission

Use a new O-ring.

Install

1. the oil pipe and dip stick pipe. Use both the screws. Tighten. See «Summary of tightening torques for specific components»(ref-415455-S06042927612011081500000)
2. a tie strap for the cable harness for the oil pipe
3. the ground lead to the engine.

Installing the left drive shaft on the transmission and the wheel spindle

Press in the constant velocity joint housing firmly so that the snap ring engages in its groove in the transmission. Pull the constant velocity joint to check that the drive shaft is secure.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Installing the sub-frame on the bodywork

Note. Use new screws. Lubricate the screw threads.

Lift up the sub-frame until it is about 150 mm from the side member.

Secure the power steering pipe at the front edge of the upper side of the sub-frame. Use the rubber covered clamp. Install the screw loosely. Apply a small amount of soap solution so that it glides into the clamp easily.

Note. Ensure the following when lifting the sub-frame

1. ensure that the brake pipe passes the bracket for the exhaust pipe
2. ensure that the ball joint pinion for the spring strut aligns in the control arm.

Install

1. the new screws and the support bracket at the rear edge
2. the screws for the bracket loosely.

Applies only to cars with fuel driven parking heaters

Align the washer with the mounting lug following the marking on the sub-frame.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

Installing the right-hand drive shaft on the transmission, wheel spindle and control arm

Install the cap for the drive shaft pilot bearing. Use 2 x M8 screws. Tighten.

Lubricate the drive shaft splines. Use a small amount of thin oil. Locate the drive shaft in the wheel hub.

Install a new screw loosely in the drive shaft.

Press down the control arm. Locate the spring strut in the ball joint pinion for the spring strut in the control arm.

Position the mobile jack lightly applied under the right side of the sub-frame.

Install

1. new screws in the sub-frame. NOTE: Lubricate the screw threads.
2. the screws loosely at the rear edge of the support plate.

Tighten the sub-frame screws. Tighten to light contact.

Remove the mobile jack.

Install the four subframe screws together with the subframe brackets and engine heater where appropriate.

Tighten to: Tightening torque . First tighten the screws on the left-hand side of the subframe followed by those on the right.

Tighten the bracket screws M10.

Installing components on the engine and sub-frame

Scheme 80

Install the 1 x M10 screw for the front engine pad. Tighten.

Loosely install the screw for the engine pad/steering gear.

Tighten the M10 screw for the rear engine pad.

Install the mounting for the engine stabilizer brace to the transmission. Use new screws. Tighten. See Summary of tightening torques for specific components .

Installing the collision protection system over the steering gear

Note. For tightening torques, see: Tightening torque .

Applies only to right-hand drive cars

Install the 2 screws. Tighten.

Checking the position of the tie rod in the steering gear

Scheme 81

Check that tie rod is in the same position as when it was removed.

Assembling the lower steering shaft

Scheme 82

Tighten the lower screw on the steering shaft joint mounting in the steering gear from the engine compartment. Use a new screw. Tighten. See: Summary of tightening torques for specific components .

Installing the cross members on the body

Scheme 83

Install

1. the M8 screws for the front member
2. the brake pipe in the holders on the member
3. the clamp with the heated oxygen sensor (HO2S) cable on the front cross member.

Installing front suspension components

HINT: Applies when installing front suspension components on both sides.

Install

1. a new M12 lock nut on the ball joint pinion. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten
2. the anti-roll bar link. Use a new M10 lock nut. Counterhold the ball joint pinion while tightening so that the boot cannot turn. Tighten. See «Summary of tightening torques for specific components»(ref-415459-S09555248762011081500000) . Tighten the drive shaft screw. Counterhold using a screwdriver in the brake disc vents. Tighten. See «Summary of tightening torques for specific components»(ref-415455-S06042927612011081500000)
3. the soundproofing over the drive shaft (applies to certain versions).

Installing components for the fender liner

Install the support plate and the nuts on both sides.

Installing the cable duct

Install

1. the cable duct on the sub-frame
2. any parking or additional heaters in the mounting in the sub-frame and the fuel line in the mountings.

Installing the front splash guard

Install

1. the splash guard under the engine
2. the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Removing the lifting beams

Lower the car.

Remove the lifting beams and hooks from the engine.

Installing the coolant hose

Install the connector securing the engine coolant hose to the heater.

Remove the hose clips.

Installing the remaining screws for the transmission and starter motor

Install

1. the 3 x M10 screws for the transmission and engine. Tighten
2. the 2 x M10 screws for the starter motor. Tighten. See «Summary of tightening torques for specific components»(ref-415306-S20035207612011081500000)
3. the bracket for the engine coolant hose and cable harness
4. the bracket for the cable harness clamp and the mounting for the heated oxygen sensor (HO2S) connector at the rear edge of the transmission
5. the clamp for the cable harness at the rear edge of the engine.

Installing the gear selector cable and oil pipe

Install

1. the ground lead and mounting on the sub-frame
2. the oil pipe on the transmission
3. the gear selector cable and bracket. Use 2 x M8 screws. Tighten.

Connect the cable to the lever. Connect the transmission connectors and the mounting for the air cleaner (ACL) housing bracket. Press the cable harness mounting into place on the control system cover.

Note. Check that the transmission bleed hose / valve is not trapped. There is a risk of overpressure in the transmission.

Installing the service clips

Note. The automatic transmission has one gear selector cable while the manual transmission has two cables.

Ensure that the gear selector cable is locked in position before installing the blue clip. Press the clip into place as illustrated.

Check that the clip is positioned in the groove as illustrated.

Installing engine compartment components

Install

1. the air cleaner (ACL) housing assembly with the intake manifold and connections
2. hook the turbocharger (TC) control valve into place in the air cleaner (ACL)
3. the upper engine stabilizer brace between the wheel arches. Use 4 x M10 screws. Tighten
4. 1 x M12 screw for the engine stabilizer brace/engine mounting. Tighten
5. the tie strap for the power steering return line in the mounting lug for the engine stabilizer brace on the right-hand side.

Fill with coolant. Carefully check while reaching operating temperature or test driving that the level remains the same and that there is no leakage.

Also see Transmission replacement, post-checking .

Installing the battery lead

Connect the battery lead.

First read Battery, disconnecting .

Finishing

Carry out checks after working on the transmission. See Transmission replacement, post-checking .

Transmission, removing

Special tools

9985972

9995185

9995460

9995463

9995562

9995681

9995716

9995972

9997070

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. Before replacing the transmission, fill in: Diagnostics/check list and enclose in the returns box.

Disconnecting the battery lead

Disconnect the battery lead. See: Battery, disconnecting .

Removing engine compartment components

Remove

1. the engine stabilizer brace between the suspension turrets and the engine
2. the air cleaner (ACL) housing assembly with the intake pipe.

Unhook the turbocharger (TC) control valve from the air cleaner (ACL) housing.

Pull the air cleaner (ACL) housing out of its mountings.

Removing components from the transmission

Remove

1. the gear selector cable. Use jimmy tool «9997077»(ref-403953-S08742937252011061000000) to detach the ball joint for the cable from the lever
2. the cable mounting from the transmission
3. the oil line from the transmission. Plug the line and the connection on the transmission cover
4. unhook the mounting with the connector for the transmission from the bracket. Separate all the connectors.

Removing the mounting screws from the transmission

Remove the bracket with the connectors for the heated oxygen sensors (HO2S) and the clamp for the cable harness from the transmission.

Remove

1. the screws for the clamp securing the cable harness at the rear edge of the engine
2. the nut for the bracket for the cable harness and the engine coolant hose
3. the 3 screws for the transmission and engine and the 2 screws for the starter motor. Tie up the cable harness.

Removing the coolant hose from the passenger compartment heater

Clamp the hoses with hose clips.

Place some paper under the inner hose connection to collect any spilled coolant.

Turn the quick-release connector (the inner of the 2 hoses) slightly in the direction of the arrow so that the lock opens. At the same time, pull the coolant hose straight out of the coolant pipe.

Note. Tie the hose up to the engine so that it does not fall down and trap the hose connector between the firewall during installation.

Installing the lifting beams and lifting hooks on the engine lifting lugs

Note. The front lifting beam must be equipped with fixture kit 9997070 as illustrated.

Position lifting beam 9995716 on the wheel arch and directly above the engine lifting eyelets on the left and right-hand sides.

Connect the lifting hooks 9995460 on the engine lifting lugs.

On the right-hand side of the engine, the hook must have a clearance of 10 mm . Also use lifting lug 9995185 on the left-hand side of the engine. Tighten to light contact on the left hand side.

Raise the car

Removing both the front wheels

Remove

1. the front splash guard. See «Sub-frame front, replacing»(ref-445738-S28904871842012010600000)
2. the splash guard under the engine.

Removing components from the sub-frame

Remove the screw for the cable duct. Unhook the cable duct from the sub-frame.

For cars with fuel powered parking heaters

Remove the 2 screws for the heater.

Unhook the heater from the mounting. Leaving it hanging in its upper mounting.

Detach the fuel line for the heater from the holders on the sub-frame.

Removing the cross members from the body

Remove

1. the clamp for the heated oxygen sensor (HO2S) cable and the screws for the front member
2. the brake pipe from the holders on the member.

Turn the member to the side so that the exhaust pipe is exposed.

Removing the screws and nuts for the engine pad, engine stabilizer brace and steering gear

Scheme 84

Remove

1. the screw for the engine pad/steering gear
2. the screw for the front engine pad
3. the screws for the engine stabilizer brace.

Measuring the position of the tie rod in the steering gear

Set the front wheels to the straight ahead position.

Lock the steering wheel. On one side, measure the length of the tie rod in relation to the steering gear housing.

Note the measurement.

Disconnecting the steering gear

Remove the screw for the joint between the steering gear and the steering shaft.

Press up the joint from the steering gear.

Removing front suspension components (both sides)

Remove

1. the soundproofing over the drive shaft (applies to certain versions)
2. the screw for the drive shaft. Counterhold using a screwdriver in the brake disc vents. Tap in the end of the drive shaft approximately 20 mm into the wheel hub
3. the link from the anti-roll bar. Counterhold using a Torx wrench in the ball joint pinion to prevent the boot from turning. (Applies to the left-hand side only.)
4. the nut for the ball joint / link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.

Disconnecting the ball joint pinion from the control arm (both sides)

Use tool 9997062 . Install cap nut 9997062 for the ball joint pinion. Tighten the nut to the control arm. Then slacken off 1 to 2 turns so that there is clearance between the cap nut and the control arm.

Position puller 9997062 on the control arm and detach the ball joint from the control arm.

Remove the tools.

Removing fender liner components (both sides)

Slacken off the 2 nuts for the fender liner and the support plate on both sides so that the fender liner can be folded out.

Removing the screws for the sub-frame support plates (both sides)

Remove the screws for the sub-frame support plates in the body (both sides).

Position mobile jack 9985972 with universal plate 9995972 , so that the plate is in light contact under the right-hand side of the sub-frame.

Slacken off the screws for the sub-frame on the right hand side. Ensure that the nuts are still secured by at least 5 threads.

Remove the jack.

Unhook the control arm from the ball joint. Install protective sleeve 9995562 . Hold the sleeve in place using the nut for the ball joint.

Work out the spring strut. Detach the drive shaft from the wheel hub. Do not damage the boot. Hold the spring strut to one side using a retaining strap for more space when removing the drive shaft.

Removing the right drive shaft

Remove

1. the support bearing cap for the drive shaft
2. the drive shaft by pulling it straight out of the transmission.

Removing the collision protection system over the steering gear

Note. Only applies to right-hand drive cars.

Remove the 2 screws for the collision protection system.

Leave the collision protection system in place on the steering gear.

Lowering the sub-frame

Note. Applies only to right-hand drive cars.

Position the mobile jack lightly applied under the left side of the sub-frame. Remove the sub-frame screws.

Note. Ensure the following when lowering the sub-frame: that the brake pipe does not catch in the bracket for the exhaust pipe mounting that the ball joint pinion releases from the control arm.

Remove the mobile jack and let the frame hang loose.

Removing the drive shaft from the wheel hub

Work out the spring strut. Detach the drive shaft from the wheel hub. Hold the spring strut to one side using a retaining strap to obtain more space when removing the transmission.

Removing the drive shaft from the transmission

Remove the drive shaft from the transmission. Use jimmy bar 9995681 .

Removing bevel gear

Remove the angle gear screws, 5. Pull the angle gear straight out from the gearbox.

Hang the bevel gear from, e.g., an oil pipe for the turbocharger or similar.

Scheme 85

Removing the rear engine mounting

Remove

1. the 3 x screws
2. the mounting and the engine pad.

Removing the screws from the torque converter

Remove the 6 screws for the torque converter. Turn the engine with a ratchet and socket. Fold out the right-hand fender liner so that the crankshaft nut can be accessed.

Use a Torx TX50 socket on the torque converter screws.

Removing the oil pipe from the transmission

Position a container under the pipe terminal.

Remove

1. the 2 screws holding the pipe. Disconnect the pipe from the transmission. Install sealing plugs in the pipe and transmission. Carefully fold the hose out of the way
2. the ground lead from the transmission.

Lowering the engine and the transmission

Lower the engine and transmission on the left-hand side. Use the hook.

Check that no hoses or cables are being stretched or trapped when the engine is lowered.

Lower the engine so that 90-100 mm of the free threads on the lifting hook can be seen.

Raise the car.

Installing the fixture on the mobile jack and transmission

Raise the car.

Install fixture 9995463 on fixture 9995972 . Use the fixture and plate together with mobile jack 9985972 . Align support plate 999 5463-2 against the fixture and the transmission.

Note. The support plate is installed on the inside of the fixture mounting lug (see the illustration). Tighten the fixture with the two torque rod screws. Apply the mobile jack lightly against the transmission.

Removing all the screws for the transmission and engine

Remove the remaining 7 screws for the transmission and engine.

Removing the transmission

Ensure that the transmission is taken straight out in relation to the engine.

Ensure that the torque converter is removed with the transmission and does not slide off the stator shaft.

Press a screwdriver through one of the screw holes in the carrier plate.

Note. Do not pry toward the carrier plate rim for the flywheel sensor.

Note. Lower the transmission slightly when it is being removed so that it will pass the side member.

Remove the transmission.

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

Special tools

9995112

9995678

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Removing the transmission: see Transmission, removing .

To remove the clutch: for gasoline see.

Note. The illustrations display a dual mass flywheel, but the method is the same for the single mass flywheels.

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Slacken off all the screws for the flywheel. Remove all the screws except for one.

Remove 9995112 .

Detach the flywheel from the crankshaft. Remove the remaining screw.

Remove the flywheel.

Checking crankshaft seal

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Note. Ensure that the mating surfaces on the crankshaft and flywheel are completely clean.

Use: 9995678 , consisting of 3 x studs with nuts.

Install

1. 3 x studs belonging to «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated
2. the flywheel.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the flywheel.

Note. Only applies to cars with dual mass flywheels: There is a marking in the form of a shallow hole (see the arrow). The marking indicates the direction to the guide hole on the flywheel.

Locate 9995112 against the flywheel.

Alternately tighten the nuts on the flywheel to the crankshaft. Use the three nuts which belong to 9995678 .

Install 7 new screws. Tighten. See Tightening torque .

Remove the 3 nuts and studs.

Install the remaining 3 new screws for the flywheel. Tighten. See Tightening torque .

Install the engine speed (RPM) sensor with the bracket. Tighten.

To install the clutch: for gasoline see.

To install the transmission, see Transmission, installing .

Special tools

9995112

9995678

Remove the transmission. Refer to: Gearbox, removing .

Remove the engine speed (RPM) sensor with the bracket. Place it to one side.

Block the carrier plate with: 9995112 .

Remove

1. all screws
2. the carrier plate
3. «9995112»(ref-403953-S01318438012011061000000) .

Check the crankshaft seal for leakage.

To replace the crankshaft seal, refer to the car model and year.

Note. For tightening torques, see: Tightening torque .

Note. Ensure that the mating surfaces on the crankshaft and carrier plate are completely clean.

Use 9995678 , which consists of 3 studs with nuts.

Install

1. The 3 studs belonging to tool «9995678»(ref-403953-S14391401472011061000000) distributed as illustrated
2. the carrier plate.

Note. Check that the locating pin on the crankshaft is positioned opposite the hole in the carrier plate.

Align: 9995112 to the carrier plate.

Pull the flywheel towards the crankshaft using the three nuts on special tool 9995678 .

Install 7 new screws. Tighten. See Summary of specific components and tightening torques .

Remove the 3 nuts and studs.

Install the remaining 3 new screws. Tighten. See Summary of specific components and tightening torques .

Install the engine speed (RPM) sensor with the bracket. Tighten.

Install the gearbox. See: Installing the gearbox .

See Crankshaft seal rear, replacing

See Crankshaft seal, front, replacing

Depressurizing the fuel system

Lower the car.

Depressurize the fuel system acc. to: Fuel system pressure release .

Scheme 86

Remove

1. the engine stabilizer brace between the suspension turrets
2. the ground strips between the engine and the firewall
3. the heat deflector plate above the turbocharger (TC)
4. the plastic charge air pipe above the engine. Seal the openings
5. the cover over the nozzle pipes
6. the cover over the ignition coils
7. the upper engine coolant hose for the engine and radiator
8. the screw holding the dip stick pipe to the intake manifold
9. the brake vacuum hose from the intake manifold.

Undo the clamp holding the plastic charge air pipe to the electronic throttle module.

Scheme 87

Remove

1. the connector from the mass air flow (MAF) sensor
2. the intake hose from the mass air flow (MAF) sensor. Seal the opening.

Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove

1. the clamp for the positive lead at the rear of the cylinder head
2. the torque bracket
3. the pipe screw for the water-heated crankcase ventilation.

Scheme 88

1. Remove the clamp for the injector wiring at the rear of the cylinder head
2. Detach the wiring from the injectors
3. Remove the fuel rail mounting screws
4. Spray universal oil or similar around the injector connectors on the intake manifold
5. Gently work the fuel rail and injectors loose
6. Separate the quick-release connector for the fuel line. See «Fuel line, lock»(ref-445696-S39060814602012010600000) .
7. Carefully put the fuel rail to one side.

Scheme 89

1. Mark up the ignition coils so that their original positions can be established
2. Remove the mounting screws for the ignition coils and the screws at the two ground terminals
3. Disconnect the connector for the variable valve timing solenoid
4. Lift up and place the ignition coils and wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel.

Scheme 90

Remove

1. The EVAP hose from the intake manifold
2. the by-pass valve vacuum hose. Disconnect the connector for the electronic throttle module (ETM)
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold
4. the pipe screw for the crankcase ventilation from the underside of the intake manifold.

Lift up and remove the intake manifold.

Note. Make sure that the fuel pressure pipe is not damaged.

Scheme 91

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that oil does not leak from the breather hole in the filler cap.

Remove the auxiliaries belt.

Remove

1. front timing cover
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

Separate the connector for the engine coolant temperature (ECT) sensor.

Scheme 92

Remove the nuts from the cover on the fender liner.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.

Remove the upper timing cover.

Removing the timing belt

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove

1. the timing belt from the timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

Removing the timing gear pulley

Remove the cable duct from its mountings on the right-hand suspension turret.

Note. Do not damage the paintwork.

Hold the cable duct out of the way and remove

1. the plug at the front of the variable valve timing unit (TX55). NOTE: Use paper or similar to absorb oil that drains.
2. the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Remove tool 9995452 .

Scheme 93

Remove

1. the heat deflector plate above the manifold
2. the upper engine coolant pipe. Place it to one side
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
5. the nuts and washers holding the manifold to the cylinder head.

Lift off the turbocharger and manifold. Carefully put them on top of the transmission.

Scheme 94

Remove

1. the screw that holds the coolant pump intake pipe to the engine block a few turns. Leave the screw in place
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Scheme 95

1. Remove the spark plugs from cylinders 1 and 5
2. Install 2 tools «9995454»(ref-403953-S30108818292011061000000) . Leave a 2-3 mm gap to the camshaft cover. NOTE: Make sure that the screw in the sparkplug thread is fully tightened. VVT-solenoid (variable valve timing).
3. The variable valve timing solenoids.
4. Remove all the screws securing the camshaft cover to the cylinder head.

Scheme 96

1. Use pliers «9995670»(ref-403953-S00526374942011061000000) to lift the cover from the cylinder head.
2. Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backwards
3. Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Scheme 97

Carefully press out the front and rear camshaft seals.

Scheme 98

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

Note. Work carefully to avoid damaging the contact faces.

When replacing or working on the cylinder head

Lift out the valve lifters. Use a magnet or suction cup.

Remove the thermostat housing and transfer it to the new cylinder head.

Note. Work carefully to avoid damaging the contact faces.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Scheme 99

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Scheme 100

1. Position the crankshaft
2. Remove the starter motor mounting screws. Pull out the starter motor and place it to one side
3. Remove the blind cover plug
4. Turn the crankshaft slightly clockwise .
5. Install crankshaft stop «9995451»(ref-403953-S26663901482011061000000) . Ensure that it bottoms out against the cylinder block.
6. Turn the crankshaft counter-clockwise until it stops against the crankshaft stop
7. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Scheme 101

1. Ensure that all studs at the exhaust ports are tightened
2. Lubricate the studs with paste 116 1408.
3. Install a new cylinder head gasket
4. Install the cylinder head
5. Lubricate and install all the screws (use new screws).
6. Tighten the screws as illustrated. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) . Use protractor «9512050»(ref-403953-S36645634772011061000000) .

Scheme 102

1. Lubricate the valve lifter wells. NOTE: If the cylinder head has been replaced, the valve clearance must be adjusted. See «Valve clearance»(ref-415512-S25672683672011081500000) .
2. Install all valve lifters
3. Lubricate the camshaft bearing positions
4. Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line
5. Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.

Scheme 103

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket ends up in the oil channels.

Installing the camshaft cover

1. Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters
2. Install the camshaft cover
3. Install press tool «9995454»(ref-403953-S30108818292011061000000) (2x).
4. Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools
5. Install all the screws. Tighten the screws from the middle and outwards
6. Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket.
2. the spark plugs. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector for the engine coolant temperature (ECT) sensor.

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Scheme 104

Install

1. new gaskets. Lift and install the manifold and turbocharger (TC)
2. the nuts and washers holding the manifold to the cylinder head
3. the upper and lower turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose
4. the pipe screws for the coolant pipes. Use new seal washers. Tighten
5. the oil pressure pipe
6. the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten. Install the heat deflector plate over the manifold.

Scheme 105

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. For cleaning, work around the shaft journal - not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Scheme 106

1. Use drift «9995718»(ref-403953-S24775656662011061000000) .
2. Lubricate the surface of the seal that the camshaft rotates against.
3. Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out
4. Remove the drift
5. Install the screw holding the inner timing cover to the cylinder head.

Checking and adjusting the variable valve timing unit

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Scheme 107

Install

1. front timing cover
2. the cable duct to the mountings on the right suspension turret
3. the auxiliaries belt
4. the expansion tank
5. the servo oil reservoir
6. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are installed correctly.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Scheme 108

Install

1. the starter motor
2. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the lower engine stabilizer brace bracket in the cylinder head
5. the upper engine stabilizer brace.

Scheme 109

Install

1. the bracket and lifting eyelet for the engine stabilizer brace bracket
2. the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
3. the clamp for the positive lead at the lifting eyelet bracket
4. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.

Connect the connector to the mass air flow (MAF) sensor. Use a clamp on the wiring at the front of the air cleaner (ACL).

Scheme 110

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the two screws in the lower row.

Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Work carefully to avoid damaging the fuel pressure pipe.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install

1. the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm
3. the hose to the canister purge (CP) valve
4. the control hose for the turbocharger (TC) by-pass valve
5. the brake vacuum hose
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
11. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Scheme 111

Install

1. the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See «Fuel line, lock»(ref-445696-S39060814602012010600000)
2. the clamp for the injector wiring at the rear of the cylinder head
3. the protective cover over the injector connectors
4. the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.

Installing components

Raise the car. Install

1. the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
2. the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
4. the lower screw for the heat deflector plate over the turbocharger (TC)
5. the splash guard under the engine
6. the plastic nuts for the hatch in the right fender liner
7. the right front wheel. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Lower the car.

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Summary of specific components and tightening torques .

Install

1. the ground strips between the cylinder head and the firewall
2. the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
3. the negative battery lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Check

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Cylinder head/gasket, replacing

Special tools

9995452

9995454

9995670

9995451

9512050

9512767

9995450

9995718

9995719

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Preparation

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the negative battery lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .
3. the right front wheel.

Removing components

Remove

1. the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
2. the pipe screw that holds the oil pressure pipe to its connector on the cylinder block
3. the oil return line. Seal the opening in the cylinder block
4. the screws and spacers at the exhaust manifold support bracket
5. the lower screw that holds the heat deflector plate over the turbocharger (TC)
6. the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe. NOTE: The front exhaust pipe's metal hose is very sensitive to twisting. Handle it with care to avoid leakage later on.

Remove

1. the engine stabilizer brace between the suspension turrets.
2. the ground strips between the engine and the bulkhead
3. the heat deflector plate above the turbocharger (TC).
4. the plastic charge air pipe above the engine. Seal the openings
5. the cover over the ignition coils
6. the upper engine coolant hose for the engine and radiator
7. the screw holding the dip stick pipe to the intake manifold.
8. the brake vacuum hose from the intake manifold.

Undo the clamp holding the plastic charge air pipe to the electronic throttle module.

Remove

1. the connector from the mass air flow (MAF) sensor.
2. the intake hose from the mass air flow (MAF) sensor. Seal the opening.

Release the hoses from the bracket at the rear of the cylinder head. Remove the bracket.

Remove

1. the clamp for the positive lead at the rear of the cylinder head
2. the torque bracket.
3. the pipe screw for the water-heated crankcase ventilation.

Removing the fuel rail

Remove the clamp for the injector wiring at the rear of the cylinder head.

Separate the fuel line quick-release connector.

Remove the fuel rail mounting screws.

Spray universal oil or similar around the injector connectors on the intake manifold.

Gently work the fuel rail and injectors loose.

Carefully put the fuel rail to one side.

Removing ignition coils

Mark up the ignition coils so that the original positions can be established.

Remove the mounting screws for the ignition coils and the screws at the two ground terminals.

Disconnect the connector for the variable valve timing solenoid.

Lift up and place the ignition coils and wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel
3. the cover at the rear edge of the intake camshaft.

Removing the intake manifold

Remove

1. the EVAP hose from the intake manifold
2. the by-pass valve vacuum hose
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws
4. the pipe screw for the crankcase ventilation from the underside of the intake manifold.

Disconnect the connector for the electronic throttle module.

Lift up and remove the intake manifold.

Note. Make sure that the fuel delivery pipe is not damaged.

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that power steering fluid does not leak from the breather hole in the filler cap.

Take off the auxiliaries belt.

Remove

1. the front timing cover
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

Separate the connector for the engine coolant temperature (ECT) sensor.

Setting up the engine

Remove the nuts from the cover on the wing liner.

Position the upper timing cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts correspond.

Remove the upper timing cover.

Scheme 112

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to 10 o'clock.

Remove

1. the timing belt from the timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

Scheme 113

Remove the cable duct from its mountings on the right-hand suspension turret.

Note. Do not damage the paintwork.

Hold the cable duct out of the way and remove

1. the plug at the front of the variable valve timing unit (TX55)
2. the center screw in the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Timing gear pulleys without variable valve timing units

Remove the screws and remove the timing belt pulley.

Remove tool 9995452 .

Removing components from turbocharger (TC)

Remove

1. the upper coolant pipe with the hose
2. the heat deflector plate above the manifold
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side.
5. the nuts and washers holding the manifold to the cylinder head.

Lift off the turbocharger and manifold. Carefully put them on top of the gearbox.

Releasing the inlet pipe for the coolant pump

Remove

1. the screw that holds the inlet pipe for the coolant pump on the cylinder block
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Removing the camshaft cover and cylinder head

Remove the spark plugs from cylinders 1 and 5.

Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover.

Make sure that the screw in the spark plug thread is tightened all the way down. VVT-solenoid.

Remove all the screws securing the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.

Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Carefully press out the front and rear camshaft seals.

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000) .
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work very carefully to avoid damaging the contact faces.

Lift out the tappets. Use a magnet or suction cup.

Note. Keep the tappets in an oil-filled container to avoid self-drainage.

Remove the thermostat housing.

Note. Work very carefully to avoid damaging the contact faces.

Cleaning

Clean the gasket faces for

1. the manifold. Check that the studs are tightened.
2. the coolant bypass channel
3. the thermostat housing.
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Position the crankshaft

Remove the starter motor mounting screws. Pull out the starter motor and place it to one side.

Remove the blind cover plug

Turn the crankshaft slightly clockwise .

Install crankshaft stop 9995451 . Ensure that it bottoms out against the cylinder block.

Turn the crankshaft counter-clockwise until it stops against the crankshaft stop

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing the cylinder head

Ensure that all studs at the exhaust ports are tightened.

Lubricate the studs with paste 116 1408.

Install a new cylinder head gasket.

Install the cylinder head

Lubricate and install all the screws. Use new screws.

Tighten the screws in the order illustrated

Tighten the screws in the following order

1. 20 Nm

2. 60 Nm .

3. Angle tighten 130° . Use protractor 9512050 .

Installing tappets and camshafts

Lubricate the valve guide wells.

Install all the tappets.

Lubricate the camshaft bearing seats.

Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line.

Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line

Applying liquid gasket

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket gets into the oil channels.

Scheme 114

Lubricate the camshaft lobes, the camshaft bearing surfaces and the tappets.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install the intake manifold and lifting eyes, tighten screws from the middle and outwards.

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket
2. the spark plugs. Tighten to 30 Nm .
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector for the engine coolant temperature (ECT) sensor.

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Install the screw for securing the coolant pump intake pipe to the cylinder block.

Installing the manifold and turbocharger (TC)

Install

1. new gaskets.

Lift and install the manifold and turbo.

1. the nuts and washers holding the manifold to the cylinder head
2. the heat deflector plate above the manifold
3. the upper turbocharger (TC) coolant pipes. Tighten the clamp on the rubber hose.
4. the pipe screws for the coolant pipes. Use new seal washers. Tighten to 26 Nm .
5. the oil pressure pipe
6. the pipe screw holding the oil pressure pipe to the turbocharger (TC). Use new seal washers. Do not tighten.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten.

Installing the rear camshaft seal

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seals

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Remove the drift.

Install the screw holding the inner timing cover to the cylinder head.

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Install

1. front timing cover
2. the cable duct to the mountings on the right suspension turret
3. the auxiliaries belt
4. the expansion tank
5. the servo oil reservoir
6. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are positioned correctly.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Install

1. the starter motor
2. the pipe screw for the water-heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm .
3. the camshaft position sensor (CMP) housing and trigger wheel
4. a new cover at the rear of the intake camshaft
5. the upper engine stabilizer brace.

Install

1. bracket and lifting eyelet for the engine stabilizer brace bracket
2. the ignition coils and ground terminals according to earlier markings.

Connect the connector for the variable valve timing solenoid.

1. the clamp for the positive lead at the lifting eyelet bracket
2. the plastic intake pipe to the mass air flow (MAF) sensor. Tighten the clamp.

Connect the connector to the mass airflow (MAF). Clamp the wiring at the front of the air cleaner (ACL).

Installing the intake manifold

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the three screws in the lower row.

Lower and twist the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Be very careful so that the fuel delivery pipe is not damaged.

Route the crankcase ventilation hose through the cavity in the intake manifold.

Install

1. the pipe screw for the crankcase ventilation on the underside of the intake manifold. Use new seal washers. Tighten to 26 Nm .
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten to 19 Nm .
3. the hose to the evaporative emission system (EVAP) valve.
4. the control hose for the turbocharger (TC) by-pass valve
5. the brake vacuum hose.
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold.

Connect the connector for the electronic throttle module (ETM).

1. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Installing the fuel rail

Install

1. the fuel rail. Use new screws.

Press the quick-release connector for the fuel pressure line until it clicks.

1. the clamp for the injector wiring at the rear of the cylinder head
2. the protective cover over the injector connectors
3. the charge air pipe over the engine. Tighten the pipe using the three screws on the engine. Tighten the clamps.

Raise the car. Install

1. the pipe screw that holds the turbocharger (TC) oil pressure pipe to the engine. Use new seal washers. Tighten to 38 Nm .
2. the turbocharger (TC) oil return line. Use a new gasket and sealing ring. Tighten to 12 Nm .
3. the clamp between the oil pressure pipe and the oil return line.
4. the screws and spacers at the manifold support bracket and cylinder block.

Tighten the three nuts that hold the front exhaust pipe to the turbocharger (TC). Tighten to 30 Nm .

1. the splash guard under the engine.
2. the plastic nuts for the hatch in the right fender liner
3. the right front wheel. See «Installing wheels»(ref-445657-S35771726922012010600000) .

Lower the car

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. Tighten to 26 Nm .

Install

1. the heat deflector plate above the turbocharger (TC).
2. the ground strips between the cylinder head and the firewall.
3. the engine stabilizer brace between the suspension turrets. Clamp the servo hose at the right engine stabilizer brace mounting.
4. the negative battery lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Replace the oil and oil filter if necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Note. There are a number of versions of the VVT-unit. Therefore, it is very important to always read the information referring to the engine variant/model year to be worked on.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the cap from the expansion tank
3. the battery negative lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .
4. the right front wheel
5. the plastic nuts on the cover at the right fender liner.

Scheme 115

Raise the car. Remove the splash guard from under the engine.

Open the engine nipple.

Drain the coolant into a container.

Close the nipple.

Remove the screw that holds the inlet pipe for the coolant pump to the cylinder block.

Scheme 116

Release the heated oxygen sensor (HO2S) wiring from the rear engine mounting.

Remove the nuts where the manifold and the front exhaust pipe divide.

Disconnect the brake pipe from the holder on the SIPS member.

Remove the screws holding the SIPS member to the bodywork.

Press the exhaust system backward.

Scheme 117

Remove

1. the cross stay between the suspension turrets
2. the hose and connector from the air assisted control valve
3. the intake hose between the mass air flow (MAF) sensor and the electronic throttle module (ETM)
4. the crankcase ventilation hose from the connection at the inlet hose
5. the cover over the ignition coils
6. the upper timing cover.

Scheme 118

Remove

1. the ground strip from the cylinder head
2. the air preheater hose between the air cleaner and the heat deflector plate above the manifold
3. the torque rod bracket
4. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head
5. the camshaft position sensor (CMP) housing and trigger wheel
6. the cover at the rear edge of the exhaust camshaft
7. the mounting screws for the ignition coil and the screws for the two ground terminals
8. the connector from the variable valve timing solenoid.

Lift up and put the ignition coils and wiring to one side.

Note. Mark up the ignition coils before removal.

Remove the crankcase ventilation hose from the top of the camshaft cover.

Remove

1. the thermostat housing
2. the heat deflector plate above the manifold
3. the manifold and gaskets.

Note. Work very carefully to avoid damaging the contact faces.

Cleaning the gasket faces

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Install

1. thermostat housing. Use a new gasket
2. the manifold. Use new gaskets. Lubricate the studs using paste 116 1408
3. the heat deflector plate above the manifold

Note. Handle the cylinder head carefully so that the gasket faces are not damaged.

Scheme 119

Install a new cylinder head gasket.

Install the cylinder head.

Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.

Use new screws. Lubricate and install all the screws.

Tighten the screws as illustrated.

Tighten the screws in the following order

1. 20 Nm .

2. 60 Nm .

3. Angle tighten 130° . Use protractor 9512050 .

Installing valve lifters and camshafts

Note. When installing a new cylinder head, the valve clearance must be set. See Valve clearance .

Lubricate the valve guide wells.

Install all the valve lifters.

Note. Make sure that the lifters end up in the same position as before.

Lubricate the camshaft bearing seats.

Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.

Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 116 1059 on the camshaft cover.

Use roller 9512767 .

The surface must be completely covered without any excess.

Scheme 120

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install all the screws. Tighten the screws from the middle and outwards.

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket
2. the spark plugs. Tighten to 30 Nm .
3. the hose for the water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.

Connect the connector to the coolant temperature sensor.

Installing the intake pipe for the coolant pump

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, P/N 116 056, to the screw threads.

Scheme 121

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. Cleaning shall be done in the direction around the shaft journal, not in and out. It is very important that any residue from the emery cloth or any other contaminants are completely removed before the new seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are wear grooves on the camshaft the seal can be pressed in another 2 mm, by turning around the tool's sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Scheme 122

Lift up the brake fluid reservoir and the expansion tank. Place them on top of engine.

Use drift 9995718 for camshaft with variable valve timing unit and drift 9995719 for camshaft without variable valve timing unit.

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Remove the drift

Install the screw holding the inner timing cover to the cylinder head.

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting .

Scheme 123

Install

1. front timing cover
2. the auxiliaries belt
3. the expansion tank
4. the servo oil reservoir
5. the bleed hose for the expansion tank. Tighten the clamp.

Check that the hoses are positioned correctly.

Connect the connectors for

1. The ABS sensor by the right suspension turret
2. the coolant level sensor in the expansion tank.

Scheme 124

Install

1. the starter motor
2. the pipe screw for the water heated crankcase ventilation at the rear of the cylinder head. Use new seal washers. Tighten to 26 Nm .
3. the trigger wheel. Ensure that the trigger wheel is correctly positioned against the camshaft
4. the camshaft position (CMP) sensor housing
5. a new cover at the rear edge of the exhaust camshaft
6. the upper torque rod bracket.

Installing the intake manifold and gasket

Note. Make sure that the gasket faces are thoroughly clean.

Install

1. a new gasket. The gasket is held in position by the lower screws for the intake manifold
2. the intake manifold. Lower and turn the pipe so that the fuel pressure pipe enters the cavity in the intake pipe at cylinders 1 and 2. NOTE: Handle the fuel delivery pipe carefully so that it is not damaged.
3. the remaining screws holding the intake manifold to the cylinder head. Tighten to 20 Nm .

Route the crankcase ventilation hose through the cavity in the intake manifold at cylinders 2 and 3.

1. all the vacuum hoses (see the illustration)
2. the screw at the support bracket under the intake manifold
3. the screw holding the dip stick pipe to the intake manifold.

Connect the throttle body (TB) connector to the engine wiring.

Installing the fuel and air distribution pipe

Lubricate the O-rings on the air distribution pipe. Use lubricant 116 1380.

Install the fuel / air distribution pipe. Use new screws.

Route the crankcase ventilation hose. Connect it to the top of the camshaft cover. Use a new clamp.

Press the quick-release connector for the fuel pressure line until it clicks. See Fuel line, lock . Pull the connection to check that it is secure.

Install

1. the connectors for the injectors
2. the cover plate over the connectors
3. the upper coolant hose. Tighten the clamp.

Install

1. the ignition coils according to the earlier markings. Check that the connectors for the ignition coils are secure
2. the screws for both the ground terminals between the ignition coils
3. the screws holding both the ground strips from the firewall to the cylinder head
4. the cover over the ignition coils
5. the upper timing cover
6. the air preheater hose between the air cleaner and the heat deflector plate above the manifold
7. the inlet hose between the mass air flow (MAF) sensor and the electronic throttle module
8. the crankcase ventilation hose to the nipple on the inlet hose
9. the hose and connector for the air assisted control valve. Tighten the clamp
10. the engine stabilizer brace between the suspension turrets Secure the servo hose to the right mounting on the support brace.

Install

1. the screw that holds the inlet pipe for the coolant pump to the cylinder block
2. the splash guard under the engine
3. the nuts for the cover in the right fender liner
4. the right front wheel «Installing wheels»(ref-445657-S35771726922012010600000) .
5. the battery negative lead. Also read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Replace the oil and oil filter.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information in the illustrations is always correct.

Note. There are a number of versions of the VVT-unit. Therefore, it is very important to always read the information referring to the engine variant/model year to be worked on.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the cap from the expansion tank
3. the battery negative lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
4. the right front wheel
5. the plastic nuts on the cover at the right fender liner.

Scheme 125

Remove

1. the cross stay between the suspension turrets
2. the preheating hose between the heat deflector plate and the air cleaner (ACL)
3. the front heated oxygen sensor (HO2S) wiring from the clips and clamps. Disconnect the wiring
4. the upper heat deflector plate
5. the nuts for the exhaust manifold.

HINT: Use rust solvent or similar on the studs.

Raise the car.

Remove

1. the front SIPS member
2. unhook the exhaust system from the rubber mounting
3. the screw in the support bracket for the exhaust manifold. Unhook the exhaust manifold from the cylinder head.

Remove

1. the intake hose between the mass air flow (MAF) sensor and the electronic throttle module (ETM)
2. the cover over the ignition coils
3. the upper timing cover.

Scheme 126

Note. Mark up the ignition coils before removal.

Remove

1. the ground strip between the cylinder head and the firewall
2. the upper and lower engine stabilizer brace
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the mounting screws for the ignition coil and the screws for the two ground terminals
5. disconnect the connector for the variable valve timing solenoid. Lift up and put the ignition coils and wiring to one side.

1. Separate the connectors for the ABS sensor and level sensor in the expansion tank
2. Lift up the expansion tank and the brake fluid reservoir. Place them on top of engine. WARNING: Make sure that no power steering fluid leaks out. It is very flammable.
3. Remove the auxiliaries belt.

Scheme 127

1. Remove the front timing cover
2. Position the upper timing cover
3. Turn the crankshaft clockwise until the markings at the crankshaft and camshafts are aligned with the markings on the oil pump and the upper timing cover
4. Remove the upper timing cover.

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.

Remove

1. the timing belt from the timing gear pulleys for the camshafts
2. the screw that holds the inner timing cover to the cylinder head.

Install tool 9995452 at the rear of the camshafts.

1. Remove the cable duct from its mountings on the right-hand suspension turret. NOTE: Do not damage the paintwork.
2. Remove the plug at the front of the variable valve timing unit (TX55). NOTE: Oil will leak out. Collect any oil using paper or similar.
3. Remove the center screw from the variable valve timing unit (TX55).

Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

Remove tool 9995452 .

Reinstall the expansion tank and the brake fluid reservoir at the right wheel arch.

Remove the two screws at the coolant pipe connection to the bypass channel.

Carefully turn the pipe to remove it from the cylinder block.

Remove

1. Variable valve timing solenoid
2. spark plugs for cylinders 1 and 5.

Install 2 tools 9995454 . Leave a 2-3 mm gap to the camshaft cover.

Ensure that the screw in the spark plug well is fully tightened.

Remove all the screws securing the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install the pliers at the stop lugs.

Start with cylinder 1 and work alternately backward.

Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Carefully press out the front and rear camshaft seals.

Note. Be very careful so that the sealing faces on the camshafts are not damaged.

Remove

1. tools 999 5454
2. the camshaft cover
3. the camshafts.

Lift out the valve lifters. Use a magnet or a suction cup.

Note. Mark up and position the lifters so that their original positions can be established.

Remove the screws holding the cylinder head on the cylinder block. Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work very carefully to avoid damaging the contact faces.

Remove the screws holding the cylinder head on the cylinder block.

Start at the sides and work alternately towards the center.

Get help to lift off the cylinder head.

Note. Work very carefully to avoid damaging the contact faces.

Remove

1. thermostat housing.

Note. Work very carefully to avoid damaging the contact faces.

Clean the gasket faces for

1. the manifold. Check that the studs are tightened and not damaged
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Aligning the crankshaft

Remove

1. the starter motor
2. the blind cover plug.

Turn the crankshaft clockwise slightly.

Install the crankshaft stop 9995451 . Ensure that it bottoms out against the engine block.

Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.

Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Install a new cylinder head gasket.

Installing the cylinder head requires help from another person.

Install the cylinder head.

Ensure that no wiring or hoses are trapped between the cylinder head and cylinder block.

Use new screws. Lubricate and install all the screws.

Tighten the screws as illustrated.

Tighten, see: Tightening torque .

Note. When installing a new cylinder head, the valve clearance must be set. See Valve clearance .

Lubricate the valve lifter wells.

Install all the valve lifters.

Note. Make sure that the lifters end up in the same position as before.

Lubricate the camshaft bearing positions.

Install the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.

Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.

Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head.

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 116 1059 on the camshaft cover.

Use roller 9512767 .

The surface must be completely covered without any excess.

Installing the camshaft covers

Lubricate the camshaft lobes, the camshaft bearing surfaces and the top of the valve lifters.

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools.

Install all the screws. Tighten the screws from the middle and outwards.

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid. Use a new gasket
2. the spark plugs. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .

Install the inlet pipe for the coolant pump on the cylinder head. Use a new gasket.

Note. Apply thread sealant, P/N 116 056, to the screw threads.

To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note. Cleaning shall be done in the direction around the shaft journal, not in and out. It is very important that any residue from the emery cloth or any other contaminants are completely removed before the new seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are wear grooves on the camshaft the seal can be pressed in another 2 mm, by turning around the tool's sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Installing the front camshaft seal

Note. The purpose of the section, "Installing the VVT-unit/timing belt pulley", described here is to make sure that the VVT-unit is positioned correctly and to reset the camshaft timing belt pulley to the correct position using the markings made at the factory. This is to make sure that the conditions are correct for any later troubleshooting.

Scheme 128

Lift up the brake fluid reservoir and the expansion tank. Place them on top of engine.

Use drift 9995718

Lubricate the surface of the seal that the camshaft rotates against.

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.

Remove the drift.

Install the screw holding the inner timing cover to the cylinder head.

Checking and adjusting

Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting

Install

1. front timing cover
2. the auxiliaries belt
3. the expansion tank
4. the servo oil reservoir
5. the bleed hose for the expansion tank. Tighten the clamp.

Check that the hoses are positioned correctly.

Connect the connectors for

1. The ABS sensor by the right suspension turret
2. the coolant level sensor in the expansion tank.

Install

1. the starter motor
2. the trigger wheel. Ensure that the trigger wheel is correctly positioned against the camshaft
3. the camshaft position (CMP) sensor housing
4. the upper torque rod bracket.

Note. Make sure that the gasket faces are thoroughly clean.

Install

1. a new gasket held in position by the lower intake manifold screws
2. the intake manifold
3. the crankcase ventilation. The crankcase ventilation must be installed through the gap between the second and third channels
4. the hose for the Positive temperature coefficient (PTC) nipple
5. the lower screws. Tighten all the screws
6. the screw at the support bracket (under the intake manifold).

Install

1. all 4 vacuum hoses on the intake manifold. (See the illustration)
2. connect the connector on the Positive temperature coefficient (PTC) nipple for crankcase ventilation (5).

Scheme 129

1. Install the fuel rail and injector nozzle
2. Press the quick-release connector together until a clicking sound is heard. See «Fuel line, lock»(ref-445696-S39060814602012010600000) . Use new screws and tighten.

Install

1. the connectors on the injectors and manifold absolute pressure (MAP) sensor in the fuel line and Positive temperature coefficient (PTC) nipple
2. the connector to the throttle body (TB).

Install

1. the cover plate over the injectors
2. the crankcase ventilation hose on the top of the camshaft cover. Use a new clamp
3. the inlet hose between the air cleaner (ACL) and throttle body (TB)
4. the cover over the ignition coils
5. the dip stick in the intake manifold
6. the clip for the power steering delivery line
7. the ignition coils according to the earlier markings. Check that the connectors for the ignition coils are secure
8. the screws for both the ground terminals between the ignition coils.

Installing the exhaust manifold

Install new gaskets.

Hook the manifold into position. Loosely install 2 nuts.

Install the rubber mounting on the exhaust system.

Install the front SIPS bracket.

Install

1. the remaining nuts for the exhaust manifold. Tighten
2. the upper heat deflector plate
3. the front wiring for the heated oxygen sensor (HO2S) using clips and clamps. Connect the wiring
4. the preheating hose between the heat deflector plate and the air cleaner (ACL)
5. the ground strip between the cylinder head and the firewall
6. the engine stabilizer brace between the suspension turrets.

Install

1. the splash guard under the engine
2. the nuts for the cover in the right-hand fender liner
3. the right front wheel «Installing wheels»(ref-415307-S16574462602011081500000)
4. the battery negative lead. Also read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Replace the oil and oil filter.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Remove

1. the radiator breather tube from the expansion tank. Install lock grip pliers
2. the battery negative lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
3. the right front wheel.

Remove

1. the clamp between the oil pressure pipe and the oil return line at the turbocharger (TC)
2. the pipe screw that holds the oil pressure pipe to the connector on the cylinder block
3. the oil return line. Seal the opening in the cylinder block
4. the lower screw that holds the heat deflector plate over the turbocharger (TC)
5. the nuts for the front exhaust pipe connection to the turbocharger (TC). Lift off the exhaust pipe and tie it up. Seal the opening in the exhaust pipe NOTE: The metal hose for the front exhaust pipe is easy to damage if it is twisted. Handle the exhaust hose with care to avoid later leakage.

Removing ignition coils

Mark up the ignition coils so that their original positions can be established

Remove the mounting screws for the ignition coils and the screws at the two ground terminals

Disconnect the connector for the variable valve timing solenoid

Lift up and place the ignition coils with wiring to one side.

Remove

1. the crankcase ventilation hose from the top of the camshaft cover
2. the camshaft position sensor (CMP) housing and trigger wheel.

Removing intake manifold

Remove

1. The EVAP hose from the intake manifold
2. the overflow valve's vacuum hose. Disconnect the connector for the electronic throttle module (ETM)
3. the upper row of screws holding the intake manifold to the cylinder head. Slacken off the lower screws. Lift up the intake manifold. Remove the pipe screw for the water heated crankcase ventilation underneath the intake manifold

Lift up and remove the intake manifold.

Note. Make sure that the fuel pressure pipe is not damaged.

Disconnect the connectors for the ABS sensor and level sensor in the expansion tank.

Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Note. Make sure that oil does not leak from the breather hole in the filler cap.

Remove

1. front timing gear casing. Pry off the auxiliaries belt
2. the hose for the water-heated crankcase ventilation from the thermostat housing.

Separate the connector for the engine coolant temperature (ECT) sensor.

Scheme 130

Install the upper belt protective cover.

Remove the nuts from the cover on the wing liner.

Turn the crankshaft clockwise until the markings on the crankshaft and camshafts match.

Remove the upper timing cover.

Scheme 131

Slacken off the center screw for the belt tensioner slightly.

Hold the center screw secure and turn the tensioner eccentric clockwise with a 6 mm Allen key to "10 o'clock".

Remove

1. the timing belt from the camshafts' timing gear pulley
2. the screw that holds the inner timing cover to the cylinder head.

Scheme 132

Install adjustment tool 9995452 at the rear of the camshafts. Screw the adjustment tool sections together into one.

Scheme 133

Remove

1. the center plugs for the variable valve timing units NOTE: Oil may drain from the VVT-units, use paper or similar to wipe up any oil
2. VVT-units' center screws. Carefully pull out the belt pulley with the VVT-unit. Remove tool «9995452»(ref-403953-S02369714572011061000000) .

Remove

1. the heat deflector plate above the manifold
2. the upper engine coolant pipe. Place it to one side
3. the oil pressure pipe for the turbocharger (TC)
4. the pipe screw at the lower coolant pipe for the turbocharger (TC). Put the pipe to one side
5. inner heat deflector plate
6. the nuts and washers holding the manifold to the cylinder head. HINT: Use rust oil or similar for easier removal of the nuts.

Lift off the turbocharger and manifold. Carefully put them on top of the transmission.

Releasing the coolant pump inlet pipe

Remove

1. the screw that holds the coolant pump's intake pipe to the engine block a few turns and leave the screw in place
2. the two screws for the connection between the coolant pipe and the bypass channel. Carefully turn the pipe to remove it from the cylinder block.

Remove

1. the spark plugs at cylinder 1 and 5. Install tool «9995454»(ref-403953-S30108818292011061000000) (2 pcs.) with 2-3 mm clearance to the camshaft cover. NOTE: Make sure that the screw in the spark plug thread is tightened all the way down
2. VVT solenoids
3. The screws holding the camshaft cover to the cylinder head.

Use pliers 9995670 to lift the cover from the cylinder head.

Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.

Slacken off the wing nuts approximately 2 turns. Repeat the procedure.

Remove

1. tools «9995454»(ref-403953-S30108818292011061000000)
2. the camshaft cover
3. the camshafts
4. the screws holding the cylinder head onto the cylinder block. Start at the sides and work alternately towards the center.

Note. Pay attention so that the contact faces are not damaged.

Get some help and lift of the cylinder head. Place the cylinder head on two wooden blocks.

When replacing/machining the cylinder head

Lift out the valve lifters. Use a magnet or suction cup.

Remove the thermostat housing and transfer it to the new cylinder head.

Note. Pay attention so that the contact faces are not damaged.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Clean the gasket faces for

1. the manifold. Check that the studs are tightened
2. the coolant bypass channel
3. the thermostat housing
4. the intake manifold
5. the cylinder block
6. camshaft cover.

Blow the oil ducts clean.

Note. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Position the crankshaft

Remove

1. the mounting screws for the starter motor and pull loose the starter motor and place it to one side.
2. the blind cover plug.

Turn the crankshaft slightly clockwise .

Install crankshaft stop 9995451 . Ensure that it bottoms out against the cylinder block.

Turn the crankshaft counter-clockwise until it stops against the crankshaft stop.

Check that the marking on the crankshaft timing gear pulley corresponds to the marking on the oil pump.

Ensure that all studs at the exhaust ports are tightened

Lubricate the studs with paste 116 1408 .

Install a new cylinder head gasket.

Get help and install the cylinder head.

Lubricate and install all the screws (use new screws).

Tighten the screws as illustrated. Tighten. See Summary of specific components and tightening torques . Use protractor 9512050 .

Lubricate the valve lifter wells.

Note. If the cylinder head has been replaced, the valve clearance must be adjusted. See Valve clearance .

Install all valve lifters

Lubricate the camshaft bearing positions

Install the intake camshaft. Ensure that the groove at the back of the camshaft is above an imaginary center line

Position the exhaust camshaft. Ensure that the groove at the back of the camshaft is below an imaginary center line.

Install new O-rings around the spark plug wells at the cylinder head.

Apply liquid gasket 1161 059 to the camshaft cover.

Use roller 9512767 . The surface must be covered without any excess .

Note. Make sure that no liquid gasket gets in to the oil channels.

Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters

Install the camshaft cover.

Install press tool 9995454 (2x).

Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head using the press tools

Install all the screws. Tighten the screws from the middle and outwards

Remove the press tools.

Install

1. the variable valve timing (VVT) solenoid (use a new gasket).
2. the spark plugs. Tighten. See «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. the hose for water-heated crankcase ventilation to the thermostat housing. Tighten the clamp.
4. the coolant pump intake pipe to the cylinder head. Use a new gasket.

Note. Apply thread sealant, 116 056 to the screw threads.

Tighten the screw for securing the coolant pump inlet pipe to the cylinder block.

Install

1. new gaskets. Lift and install the manifold and turbocharger (TC)
2. washers and nuts that hold the manifold to the cylinder head and tighten according to «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. turbo's upper and lower coolant pipes according to «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
4. union screws for the coolant pipes (use new sealing washers). Tighten according to «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
5. the oil pressure pipe
6. the union screw that holds the oil pressure pipe to the turbocharger (use new sealing washers). Do not tighten.
7. inner heat deflector plate.

Lubricate the studs on the turbocharger (TC). Use paste 116 1408 .

Install the front exhaust pipe onto the turbocharger (TC). Use new nuts. Do not tighten. Install the heat deflector plate over the manifold.

Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Note. Clean in the direction around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other impurities are completely removed before the new seal ring is installed.

Use drift 9995450 .

Lubricate the surface of the seal that the camshaft rotates against.

Press in the seal until the drift bottoms out.

Note. If there are grooves on the camshaft, the seal can be pressed in a further 2 mm: Reverse the sleeve.

Install camshaft adjustment tool 9995452 at the rear of the camshafts.

Ensure that the screws retaining the adjustment tool to the camshafts and the screws holding the tool together are well tightened.

Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Note. Clean in the direction around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other impurities are completely removed before the new seal ring is installed.

Scheme 134

Lubricate the surface of the seal that the camshaft rotates against.

Install the camshaft seal. Use drift 9995718 .

Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out

Checking crankshaft setting

Turn the crankshaft counter-clockwise until it stops against the adjustment tool.

Check that the marking on the crankshaft timing gear pulley corresponds to the marking on the oil pump.

Installing VVT-unit/timing gear pulley on exhaust camshaft

Note. The section "Installing the VVT-unit/timing gear pulley" described here is to make sure that the VVT-unit is positioned correctly and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later troubleshooting.

Scheme 135

Loosen, do not remove the screws that hold the timing gear pulley to the VVT-unit.

Press the VVT-unit/ timing gear on the camshaft.

Install the center screw that holds the VVT-unit to the camshaft. Tighten slightly .

Turn the variable valve timing unit counter-clockwise as far as it will go.

Remove the center screw.

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing gear pulley's marking is 1 tooth before the marking on the upper timing gear casing.

Note. Do not turn counter-clockwise during this procedure.

Check that the timing gear pulley is still in its end-position at the oval holes.

Tighten the VVT-unit's center screw according to Summary of specific components and tightening torques .

Check that the VVT-unit does not rotate when tightening.

Install the center plug. Tighten according to Summary of specific components and tightening torques .

Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Scheme 136

Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit.

Press the variable valve timing unit / timing gear onto the camshaft.

Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.

Turn the variable valve timing unit counter-clockwise as far as it will go.

Remove the center screw.

Position the upper timing cover.

Turn the timing gear pulley clockwise until the screws at the oval holes are in the end-position. Continue turning clockwise until the timing gear pulley marking is 1 1/2 teeth before the marking on the upper timing gear casing.

Note. Do not turn counter-clockwise during this procedure.

Scheme 137

Check that the timing gear pulley is still in its end-position at the oval holes.

Tighten the center screw in the VVT unit. See Summary of specific components and tightening torques .

Check that the VVT-unit does not rotate when tightening.

Install and tighten the center plug according to Summary of specific components and tightening torques .

Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Tighten the center screw for the timing belt tensioner. Tighten to 5 Nm .

Scheme 138

Tighten the center screw on the belt tensioner with 5 Nm .

Install the belt as follows

1. crankshaft
2. the idler pulley
3. intake cam
4. exhaust cam
5. water pump
6. tension pulley.

Note. The VVT-units do not have a return spring and are easily dislodged when installing the timing belt. Check that the markings match.

Scheme 139

This adjustment is carried out on a cold engine where a suitable temperature is approx. 20°C / 68°F.

At a higher temperature, for example, with a warm engine or a higher ambient temperature, the needle assumes a position farther to the right.

The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Hold the center screw secure and turn the eccentric on the belt tensioner counter-clockwise until the tensioner's indicator passes the marked position.

Tighten the screws on the timing gear pulley for the exhaust camshaft according to Summary of specific components and tightening torques .

Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See Summary of specific components and tightening torques .

Scheme 140

Note. Check that the VVT-units are in their end-position.

Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.

Hold the eccentric secure and tighten the center screw according to Summary of specific components and tightening torques .

Check that the indicator is in the correct position.

Remove

1. camshaft adjustment tool «9995451»(ref-403953-S26663901482011061000000) .
2. crankshaft stop «9995452»(ref-403953-S02369714572011061000000) . Install the plug with new sealing washer. Tighten according to «Tightening torque»(ref-415313-S04581247082011081500000) .

Scheme 141

Press on the timing belt to check that the indicator on the tensioner moves easily.

Install the upper timing belt cover.

Turn the crankshaft two revolutions and check that the markings on the crankshaft's and camshafts' gear pulleys match.

Check that the indicator on the belt tensioner is within the marked position.

Remove the upper timing cover.

Install

1. the trigger wheel. Tighten the screw
2. the camshaft position (CMP) sensor housing. Tighten the screws
3. the lower and upper torque rod bracket on the cylinder head. Tighten according to «Tightening torque»(ref-415313-S04581247082011081500000) .

Install

1. screw for the inner timing gear casing
2. front timing cover
3. the cable duct to the mountings on the right suspension turret
4. the auxiliaries belt
5. the expansion tank
6. the servo oil reservoir
7. the bleed hose to the expansion tank. Tighten the clamp.

Check that the hoses are correctly positioned.

Connect the connectors for the ABS sensor at the right suspension turret and for the coolant level sensor in the expansion tank.

Install

1. the starter motor
2. union screw for water-heated crankcase ventilation at the cylinder head's trailing edge. Use new sealing washers and tighten down.
3. the camshaft position sensor (CMP) housing and trigger wheel
4. the lower engine stabilizer brace bracket in the cylinder head
5. the upper engine stabilizer brace
6. bracket for hoses on lower torque rod bracket.

Install

1. the bracket/lifting eye for the torque rod bracket
2. the ignition coils and ground terminals according to earlier markings. Connect the connector for the variable valve timing solenoid
3. the clamp for the positive lead at the lifting eyelet bracket

Installing intake manifold

Clean the intake manifold gasket face to the cylinder head.

Install a new gasket on the cylinder head. Secure with the two screws in the lower row.

Lower the intake manifold so that the fuel pressure line goes through the cavity in the intake manifold.

Note. Take care not to damage the fuel pressure pipes.

Route crankcase ventilation hose between cylinder 2 and 3.

Install

1. the union screw for the crankcase ventilation on the underside of the intake manifold. Use new sealing washers. Tighten according to «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
2. the rest of the screws holding the intake manifold to the cylinder head. Tighten according to «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. the hose to the canister purge (CP) valve
4. the control hose for the turbo's overflow valve
5. the brake vacuum hose
6. the crankcase ventilation hose to the top of the camshaft cover. Use a new clamp
7. the cover over the ignition coils
8. the upper timing cover
9. the upper engine coolant hose for the engine and radiator. Tighten the clamp
10. the screw holding the dip stick pipe to the intake manifold. Connect the connector to the electronic throttle module (ETM)
11. the charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Remove the seal. Tighten the clamp.

Install

1. the fuel rail. Use new screws. Press the quick-release connector for the fuel pressure line until it clicks. See «Fuel line, lock»(ref-445696-S39060814602012010600000)
2. clamp for the injectors' wiring at the cylinder head's trailing edge. Plug in connectors for injectors and fuel pressure sensor as well as water temperature sensor.

Install

1. the protective cover over the injector connectors
2. the charge-air pipe over the engine. Tighten the pipe using the three screws by the engine. Tighten the clamps
3. fresh air hose between turbo and air filter
4. air filter assembly with mass air flow sensor. Plug in connector for mass air flow sensor and tighten the clamp.
5. the inlet hose between the air filter and the front cover plate

Raise the car. Install

1. the union screw that holds the turbocharger's oil pressure pipe to the engine. Use new sealing washers. Tighten and refer to: «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
2. the turbocharger's oil return line. Use a new gasket and sealing ring. Tighten refer to: «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000)
3. the clamp between the oil pressure pipe and the oil return line. Tighten the three nuts that hold the front exhaust pipe to the turbocharger refer to: «Summary of specific components and tightening torques»(ref-415313-S41605237922011081500000) .
4. the lower screw for the heat deflector plate over the turbocharger (TC)
5. the splash guard under the engine. (Only applies to cars with automatic transmission)
6. the plastic nuts for the hatch in the right wing liner
7. right front wheel. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Lower the car.

Tighten the pipe screw for the turbocharger (TC) oil pressure pipe. See Summary of specific components and tightening torques .

Install

1. the ground strips between the cylinder head and the firewall
2. the engine stabilizer brace between the suspension turrets Clamp the servo hose at the right-hand engine stabilizer brace mounting
3. battery's minus cable. First read: «Battery, disconnecting»(ref-415278-S03862267492011081500000)

Fill up engine with coolant.

Change the oil and replace the oil filter as necessary.

Check

1. the engine oil level
2. the servo oil level
3. the coolant level.

Warm up the engine until the thermostat opens.

Check the engine for leaks.

Top up the coolant if necessary.

Replacing the front sub-frame

Special tools

9995716

9995460

9995045

9512050

Scheme 142

1. Diesel only . Remove the engine cover
2. Install lifting beam «9995716»(ref-403953-S41765249862011061000000) . Install lifting hooks «9995460»(ref-403953-S32932431362011061000000)
3. Lift the engine to relieve the load on the engine pads.

Scheme 143

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 144

1. the air duct cover.

Scheme 145

1. the cable duct screw.

Scheme 146

Remove

1. the oil pipes from the steering gear from the snap fasteners on the sub-frame
2. the hose for the EVAP canister along the sub-frame (does not apply to diesel cars)
3. the fuel line for the engine block heater and the engine block heater (if applicable) on the left side of the sub-frame.

Scheme 147

Remove

1. the hose for the EVAP canister in the joint by pulling apart the hose. Pull it forwards under the anti-roll bar and remove it from the snap fastener on the sub-frame. (Does not apply to Diesel).

Scheme 148

Remove

1. the mounting for the exhaust pipe on the bracket
2. the screws holding the exhaust pipe bracket. Disconnect the brake pipe from the snap fasteners on the bracket
3. the bracket.

Scheme 149

1. Remove the heated oxygen sensor (HO2S) wiring from the mounting. (Does not apply to Diesel).

Scheme 150

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

Scheme 151

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

Scheme 152

1. Remove the front engine pad screw.

Scheme 153

1. Slacken off the right lower front section of the fender liner
2. Remove the plastic nuts on the fender liner
3. Remove the splash guard
4. Bend out the fender liner.

Scheme 154

1. Remove both the right hand engine mounting screws.

Scheme 155

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

Scheme 156

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

Scheme 157

1. Remove and hang up the engine block heater (if applicable) on the left front mounting for the sub-frame
2. Position a lifting table under the sub-frame
3. Remove the screws holding the sub-frame brackets to the bodywork on both sides
4. Remove the four screws from the sub-frame
5. Carefully lower the sub-frame. NOTE: Ensure that the steering gear screws are released from the sub-frame.

Scheme 158

Hang the steering gear from a hook 9995045 so that the lower steering shaft does not come apart.

On right-hand drive cars the hook is installed on the right-hand side.

Scheme 159

Transfer

1. the control arms. Use new screws and new nut. Tighten the front screws. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) . Tighten the rear screw. Tighten to 105 Nm . Angle-tighten 90°
2. the anti-roll bar. Tighten to 60 Nm
3. the right-hand engine mounting. Tighten the screws. Tighten to 65 Nm . Angle-tighten 60°
4. the mounting for the heated oxygen sensor (HO2S) wiring
5. the engine pad.

Install new pipe / hose holders.

Installing the sub-frame

1. Position the sub-frame on a lifting table
2. Carefully lift the sub-frame
3. Locate the control arms on the ball joints and the steering gear on its mountings
4. Remove the hook (999 5045) that is holding the steering gear
5. Lift the sub-frame up completely
6. Reinstall the engine block heater (if applicable).

1. Install the engine block heater (if applicable) on the left front mounting for the sub-frame
2. Install the four screws in the subframe together with the sub-frame brackets. Use new screws . Lubricate the screws
3. First tighten the screws on the left-hand side of the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Then tighten the right-hand side to the same values
4. Finally tighten the screws for the brackets on both sides to 50 Nm .

Install

1. the right-hand engine mounting. Use new screws. Tighten to 35 Nm . Angle-tighten 90° .

1. the front engine pad. Tighten to 50 Nm .

1. lower torque rod. Tighten the screw and nut. Tighten to 35 Nm . Angle-tighten 90° . The lower torque rod must be tightened last to avoid tension being introduced. Tighten the front nuts. Tighten to 65 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

Note. Use new screws and nuts.

1. the fender liner and the splash guard with both the plastic nuts.

1. the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm . Clip the cable in position. The nut (A), holding the lower half of the collision protection. (Applies only to right-hand drive cars). Tighten to 50 Nm .

Scheme 160

1. the wiring for the heated oxygen sensor (HO2S) in its mounting. (Does not apply to diesels).

1. the mounting for the exhaust pipe on the bracket. Tighten to 10 Nm
2. the brake pipe on the exhaust pipe bracket
3. the exhaust pipe bracket. Tighten the bracket screws. Tighten to 25 Nm .

1. EVAP canister hose. Press the joint together. (Does not apply to Diesel).

1. the oil pipe to the steering gear
2. the hose for the EVAP canister (Does not apply to diesel)
3. any fuel line for engine block heater
4. the engine block heater (if applicable) on the left front mounting for the sub-frame.

1. new nuts on the ball joints. Tighten to 80 Nm . Counterhold with a Torx wrench so that the ball joint boot is not damaged.

1. the anti-roll bar links. Use new nuts. Tighten to 50 Nm . Counterhold with a Torx wrench so that the boot is not damaged.

1. the cable duct screw.

1. the air duct cover.

Install

1. the splash guard under the engine. Tighten to 20 Nm
2. Lower the car.

1. Install the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000)
2. Remove the lifting tools for the engine
3. Install the engine cover (Applies only to diesel engines).

Scheme 161

Remove

1. the screw for the torque rod mounting in the torque control arm and bracket on the engine
2. the screws at the suspension turrets
3. the torque rod.

Scheme 162

Transfer

1. the brackets (A) on the left and right-hand sides to the new torque rod. Do not tighten yet.

Scheme 163

Install

1. the torque rod
2. the screws for the brackets at the suspension turrets. Tighten to 50 Nm .
3. the screw and nut for the torque rod mounting in the torque control arm/bracket on the engine. Tighten to 85 Nm .

Tighten the torque rod to the brackets to 85 Nm .

Bushing sub-frame, replacing

Special tools

9995716

9995460

9995717

9995589

9995352

9995457

9995567

9995575

9995576

9512564

9512050

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 164

Remove the engine cover ( applies only to diesel ).

Install lifting tools 9995716 and lifting hooks 9995460 .

Lift the engine to relieve the load on the engine pads.

Remove

1. the front wheels
2. the splash guard under the engine.

Scheme 165

1. the air baffle.

1. the screw for the cable duct
2. the control module box evacuation pipe mounting from the sub-frame.

Scheme 166

Remove the lower screw for the front engine pad.

Folding out the fender liner

Slacken off the right lower front part of the fender liner.

Remove the plastic nuts on the fender liner.

Remove the cover plate.

Bend out the fender liner.

Scheme 167

Remove the screws holding the right-hand engine mounting in the engine.

Removing the nuts and screw for the steering gear

Remove

1. the four nuts and screws holding the steering gear
2. the nut (A), holding the lower half of the collision protection ( only applies to right hand drive cars ).

Removing the delivery line for the steering gear

Remove the delivery pipe for the steering gear from the snap fasteners along the sub-frame

Remove the hose for the EVAP canister (does not apply to diesel cars)

Remove the fuel line for the engine block heater (if applicable).

Scheme 168

Remove and hang the engine block heater (if applicable) on the left front mounting for the sub-frame.

Remove the fuel line for the engine block heater (if applicable) on the sub-frame from the snap fasteners.

Position a lifting table under the sub-frame.

Apply the lifting table so that the load is taken off the sub-frame screws.

Remove the sub-frame screws together with the accompanying brackets and washers.

Carefully lower the sub-frame approximately 50 mm.

Note. Ensure that the steering gear screws are released from the sub-frame.

Scheme 169

Remove the bracket for the heated oxygen sensor (HO2S) from the sub-frame ( does not apply to diesels ).

Lower the sub-frame a further 40 mm.

Scheme 170

Install the hydraulic tool and press sleeve as illustrated.

Press the bushings out of the sub-frame, see the following illustration.

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Installing the bracket for the heated oxygen sensor (HO2S)

Lift up the sub-frame slightly, approximately 50 mm from the car body.

Install the wiring for the heated oxygen sensor (HO2S) on the sub-frame (does not apply to diesel cars).

Scheme 171

Scheme 172

Clean the hole for the bushing in the sub-frame.

Press out the bushing by hand.

Marking the left-hand rear bushing

Note. The left-hand rear bushing on the sub-frame is a different version to the other three bushings. The hole in the center of the bushing is oval. The oval must be positioned lengthways to the car, as illustrated.

Scheme 173

Install the hydraulic tool and press sleeve as illustrated.

Press the bushings into the sub-frame, see the following illustration.

Note. It is arbitrary which of tools 999 5575, 999 5576 and 951 2564 is used.

Scheme 174

Lifting the sub-frame

Lift the sub-frame up completely.

At the same time locate the mounting screws for the steering gear on the sub-frame and, on right-hand drive cars, the screw for the collision protection system.

Install the sub-frame brackets loosely together with the washers.

Install the four screws for the sub-frame. Use new screws. Do not tighten yet .

First tighten the screws on the left side of the sub-frame. Tighten to 105 Nm . Angle tighten 120° . Then tighten the right-hand side to the same values as the left side.

Finally tighten the screws for the brackets on both sides. Tighten to 50 Nm .

Install the engine block heater (if applicable) on the left front mounting for the sub-frame.

Installing the nuts and screw for the steering gear

Install

1. the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm .

Applies to right-hand drive cars

1. nut (A), holding collision protection lower half. Tighten to 50 Nm .

Installing the delivery line from the steering gear

Install the delivery pipe from the steering gear along the mountings on the sub-frame.

Install the hose for the EVAP canister.

Install the fuel line for the engine block heater (if applicable).

Installing the screws for the engine mounting to the engine

Reinstall the screws holding the engine mounting to the engine. Tighten to 35 Nm . Angle-tighten 90° .

Note. Use new screws.

Installing the protective plate

Install

1. the right lower front section of the fender liner
2. the protective plate
3. the plastic nuts for the protective plate.

Installing the screw for the front engine pad

Install the front engine pad screw. Tighten to 50 Nm .

Installing the air intake cover

Install

1. the screw for the cable duct
2. the evacuation pipe on the sub-frame.

1. the air baffle.

Installing the protective cover

Install the splashguard under the engine.

Removing the lifting tools

Lower the car.

Remove the lifting tools.

Install the wheels. See Installing wheels .

Removing the rear engine pad

Preparation

Remove

1. the screw holding the mounting for the torque rod at the bracket on the engine
2. the screws for the engine stabilizer brace mounting on the suspension turrets
3. the engine stabilizer brace.

Scheme 175

Remove

1. the upper nut for the rear engine pad.

Raise the car

Remove

1. the splash guard under the engine.

Scheme 176

Remove

1. both the screws for the mounting and the brake pipe from the snap fastener
2. angle the mountings forward
3. the catalytic converter member.

Scheme 177

Remove

1. the bracket for the heated oxygen sensor (HO2S) from the sub-frame
2. the lower screw for the engine pad.

Scheme 178

1. Remove the screw and nut at the lower torque rod mounting to the bracket on the transmission
2. Position a mobile jack under the transmission
3. Carefully lift up the engine so that the engine pad can be replaced
4. Install the new engine pad
5. Install a new screw in the lower mounting for the engine pad. Do not tighten yet
6. Carefully lower the engine
7. NOTE: Ensure that the guide pin for the engine pad locates correctly.
8. Remove the mobile jack.

Installing the rear engine pad

Finishing

1. Install a new screw and nut on the lower torque rod. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

1. Tighten the lower engine pad screw. Tighten to 50 Nm
2. Install the bracket for the heated oxygen sensor
3. Install the splashguard under the engine. Tighten to 25 Nm .

Install

1. both the screws for the mountings for the three-way catalytic converter (TWC) member. Tighten to 10 Nm
2. the brake pipe on the catalytic converter member
3. the catalytic converter member. Tighten to 25 Nm .

Lower the car.

Install

1. a new nut in the upper mounting for the engine pad. Tighten to 50 Nm .

Scheme 179

Install

1. the engine stabilizer brace between the suspension turrets. Tighten the four screws. Tighten to 50 Nm
2. the screw for the engine stabilizer brace mounting at the torque control arm on the engine. Tighten to 80 Nm .

Remove

1. the battery lead. See «Battery, disconnecting»(ref-415278-S03862267492011081500000)
2. the torque rod. See «Replacing the torque rod»(ref-415305-S24543473942011081500000) .

Scheme 180

Remove

1. the nut on the top for the engine pad
2. raise the car.

Remove

1. the splash guard and the air intake cover under the engine
2. the screw for the engine pad.

Scheme 181

1. Remove the screw and nut at the lower torque rod mounting to the bracket on the transmission
2. position a mobile jack with universal plates «9995972»(ref-403953-S08076234722011061000000) under the transmission
3. Check that the plate does not catch in the sub-frame
4. carefully lift up the engine so that the engine pad can be replaced.

1. install a new screw in the lower mounting for the engine pad. Do not tighten yet
2. carefully lower the engine
3. NOTE: Ensure that the guide pin at the top of the engine pad locates correctly.
4. remove the mobile jack.

1. Use a new screw and nut on the lower torque rod. Tighten to 35 Nm . Angle-tighten 90° . Use bevel protractor «9512050»(ref-403953-S36645634772011061000000) .

1. Tighten the lower screw in the engine pad. Tighten to 50 Nm
2. Install the splash guard and the air baffle cover under the engine
3. Lower the car.

Install

1. the nut on the top of the engine pad. Tighten to 50 Nm
2. the charge air pipe to the charge air cooler (CAC)
3. the air intake between the air cleaner and the front panel
4. the torque rod. See «Replacing the torque rod»(ref-415305-S24543473942011081500000)
5. the battery lead. See «Battery, disconnecting»(ref-415278-S03862267492011081500000)

Engine mount, right, replacing

Special tools

9512050

9995972

See Bushing sub-frame, replacing

Engine mount rear, replacing

See Engine mount rear, replacing

Engine mount, front, replacing

See Engine mount, front, replacing

See Engine mount, right, replacing

See Bushing sub-frame, replacing

See Engine mount rear, replacing

See Engine mount, front, replacing

See Engine mount, right, replacing

See Engine mount, right, replacing

See Bushing sub-frame, replacing

See Engine mount rear, replacing

See Engine mount, front, replacing

See Engine mount, right, replacing

See Bushing sub-frame, replacing

See Engine mount rear, replacing

See Engine mount, front, replacing

See Engine mount, right, replacing

See Bushing sub-frame, replacing

See Engine mount rear, replacing

See Engine mount, front, replacing

See Engine mount, right, replacing

Engine/transmission, installing

Special tools

9512050

9995972

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. For tightening torques, see Tightening torque

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Scheme 182

Raise the engine and the transmission unit. Use a lifting table with locating pins.

Stop when the sub-frame is approximately 15 cm below the frame members.

Scheme 183

Install (left and right-hand sides)

1. the drive shaft to the hub. Install the center screws. Do not tighten yet.
2. the ball joint to the control arm. Install the nuts. Do not tighten yet. NOTE: Ensure that the mating surfaces on the ball joints and control arms are clean.

Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.

Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.

Align the steering shaft joint on the steering gear.

Lift the engine and transmission unit up to the frame members.

Note. Ensure that no hoses, wiring or anything else catches.

Install

1. a new screw in the lower steering shaft joint. Tighten to 20 Nm
2. new screw in the sub-frame. Lubricate the screws
3. the washes at the front edge and the support plates at the rear edge of the sub-frame.

Tighten the screws for the sub-frame. Tighten to 105 Nm . Angle-tighten 120° . Use bevel protractor 9512050 . Start on the left hand side of the sub-frame. Continue with the right hand side.

Tighten the screws for the brackets at the rear of the sub-frame. Tighten to 50 Nm .

Remove the lifting table.

Installing the propeller shaft (all-wheel drive (AWD) only)

Install the propeller shaft (all-wheel drive (AWD) only). See Pinion seal bevel gear, replacing .

Installing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)

Lubricate the studs where the exhaust system separates downstream of the three-way catalytic converter (TWC). Use paste 116 1408.

Lift up the exhaust system and connect it to the rear system. Use a new gasket and new nuts.

HINT: Use a mobile jack with universal plate 9995972 as a support.

Note. The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.

Install the screws holding the SIPS member to the bodywork. Tighten the screws.

Press the brake pipe into place in the holders on the SIPS member.

Installing the front exhaust pipe

Lubricate the studs on the turbocharger (TC). Use paste 116 1408.

Install the front exhaust pipe on the turbocharger (TC). Use new nuts. Tighten to 30 Nm .

Clamp the wiring for the rear heated oxygen sensor (HO2S) into place at

1. the bracket at the rear of the sub-frame
2. the clips on the power steering pipe at the steering gear
3. the clamp at the right-hand side of the steering gear.

Scheme 184

When assembling the fuel lines, see also: Fuel system, quick-release connectors .

Connect the quick-release connector and the fuel line to

1. the motor
2. the engine block heater (option).

Press the EVAP line together at the rubber joint.

Scheme 185

Install

1. the tie rods. Use new nuts. Tighten to 70 Nm
2. the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm . Counterhold with Tx27
3. the bracket for the brake pipe to the body.

Tighten

1. the nut for the ball joint and control arm. Tighten to 80 Nm . Counterhold using Tx40
2. the center screw in the drive shaft. Tighten to 50 Nm .

Scheme 186

Connect the heater connector at the vehicle wiring.

Ensure that the connector and wiring are secured at the body.

Rivet the fender liner to the fender edge.

Check that the quick-release fuel line connector is secure at the engine block heater.

Scheme 187

Install the 4 screws while the compressor is loose.

Raise the compressor and screw it into place.

Note. Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes.

Connect the one-pin connector to the compressor magnetic clutch.

Scheme 188

Connect the engine wiring to the control module box. See Central electrical unit, engine compartment, replacing .

Install

1. the ground lead to the ground terminal at the right fender edge in the engine compartment
2. the auxiliaries belt
3. the intermediate piece for the control module box
4. the control modules. See «Engine control module (ECM), replacing»(ref-415281-S12652924142011081500000)
5. the cover for the control module box
6. expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
7. servo oil reservoir. Check that the hoses are correctly positioned.

Clamp the ABS cable to the power steering hose.

Scheme 189

Install

1. the heat deflector plate above the turbocharger (TC)
2. the 2 ground strips on the top of the cylinder head.

Clamp the wiring for the front heated oxygen sensor (HO2S) to

1. the coolant pipe
2. the heat deflector plate above the manifold
3. the turbo control hose at the plastic intake pipe for the turbocharger (TC).

Scheme 190

Install

1. the positive lead for the starter motor
2. the connector for the engine wiring
3. the cover over the central electrical unit.

Installing the transmission cable

Automatic transmissions : Install the screws holding the bracket and transmission cable to the transmission.

Manual transmissions : Install the transmission cable. Assemble the clutch cable. See Transmission, installation .

Scheme 191

Install

1. the lower engine coolant hose to the radiator. Tighten the clamp
2. the lower oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings
3. the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Only connect the plastic pipe at the throttle body (TB). Do not tighten the clamp.

Remove radiator protection 999 5474

Install

1. the engine cooling fan (FC). Tighten the screws securing the fan shroud to the front panel
2. the plastic charge air pipe to the connection at the charge air cooler (CAC). Tighten both the clamps. Connect the connectors for the temperature and pressure sensors in the plastic pipe
3. the canister purge (CP) valve to the bracket at the fan shroud. Secure the EVAP hose to the clip at the lower section of the fan shroud
4. the brake vacuum hoses
5. the upper oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings.

Scheme 192

Press down the right side of the cooler unit. Pull the wiring for the pressure switch (Pressostat) into the drier bottle.

Connect the connectors to

1. the engine cooling fan (FC) (x2)
2. the canister purge (CP) valve.

Secure

1. the breather tube for the radiator at the top of the fan shroud
2. the wiring at the lower right corner and at the top of the fan shroud.

Install

1. the rubber hose to the inlet side of the charge air cooler (CAC)
2. the plastic charge air pipe above the engine. Tighten all clamps. Secure the pipe on the engine
3. the upper coolant hose. Tighten the clamp
4. the ventilation pipe between the control module box and fan shroud
5. the air cleaner (ACL) assembly. Connect the plastic hose to the mass air flow (MAF) sensor. Tighten the clamp
6. the air cleaner (ACL) intake pipe.

Connect the connector to the mass air flow (MAF) sensor. Secure the wiring at the front of the air cleaner (ACL) housing.

Install the support brace between the suspension turrets. Secure the servo hose to the right mounting on the support brace.

Scheme 193

Connect the connector to the pressure switch (Pressostat) in the drier bottle. Secure the wiring.

Tighten the lower screw on the cooler unit.

Connect the connectors to both the heated oxygen sensors (HO2S).

Scheme 194

Install

1. the splash guard under the radiator
2. the splash guard under the engine
3. the front wheels. See «Installing wheels»(ref-445657-S35771726922012010600000)
4. the battery negative lead. Also read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Final check

Top up

1. coolant
2. engine oil
3. power steering fluid.

Start the engine.

Warm up the engine until the thermostat opens.

Check for leakage.

Check the oil and coolant levels. Adjust if necessary.

Check the transmission oil level (automatic transmissions only). Top up if necessary.

Engine/transmission, removing

Special tools

9995474

9995722

Note. Since the illustrations in the information are used for different model years and/or models, there may be some deviations. However, the essential information is always correct.

Remove

1. the negative battery cable. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .
2. the cross stay between the suspension turrets
3. the air cleaner (ACL) assembly. Seal the opening in the plastic pipe for the turbocharger (TC)
4. the plastic charge air pipe above the engine. Seal the openings
5. both the ground strips at the top of the cylinder head.

Remove

1. the cover over the central electrical unit
2. the connector for the engine wiring from the central electrical unit
3. the positive lead for the starter motor from the terminal block.

Scheme 195

Remove

1. control module unit cover
2. the control modules. Use tool «9995722»(ref-403953-S10522720692011061000000) . See also «Engine control module (ECM), replacing»(ref-415281-S12652924142011081500000) .

Separate the control module box. Disconnect the engine wiring. Also see Central electrical unit, engine compartment, replacing .

Remove the ground terminal for the engine wiring at the right wheel arch.

Scheme 196

Remove

1. the brake vacuum hose from the ejector valve
2. The canister purge (CP) valve from the mounting on the fan shroud. Disconnect the connector.

Expose the wiring and the breather tube for the radiator.

Disconnect the connectors for the engine cooling fan (FC).

Remove

1. the screws securing the fan shroud to the front panel
2. the dip stick
3. the upper oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.

Lift up and remove the engine cooling fan (FC).

Remove

1. the connectors for the pressure sensor and temperature sensor in the plastic charge air pipe between the charge air cooler (CAC) and the throttle body (TB)
2. the rubber hose at the intake for the charge air cooler (CAC)
3. the brake vacuum hose at the intake manifold
4. the plastic pipe between the throttle body (TB) and the charge air cooler (CAC)
5. the lower oil hose for the transmission at the connection to the radiator (automatic transmissions only). Seal the openings.

Install radiator protection 9995474 .

Removing the transmission cable

Automatic transmissions : Remove the screws for the transmission cable bracket at the transmission.

Manual transmissions : Separate the clutch cable and remove the transmission cables. See Transmission, removing .

Tie up the cable(s) to the central electrical unit.

Raise the car.

Remove

1. the left and right front wheels
2. the splash guard under the radiator
3. the splash guard under the engine.

Scheme 197

Position a container under the radiator drain cock.

Drain the coolant.

Close the cock.

Cars with engine block heaters (option)

Drill out the first three blind rivets at the right mounting for the fender lining to the fender edge, seen from the front edge and upwards.

Bend the fender liner out of the way.

Disconnect the connector from the engine block heater.

Separating the fuel line

Note. If an engine block heater is installed, mark the position of the fuel lines.

Separate the quick-release connectors for the fuel pressure line and engine block heater (option). See also: Fuel system, quick-release connectors .

HINT: Use tool 9995666 .

Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.

Scheme 198

Remove the screw from the wiring clamp that holds the wiring for the heated oxygen sensor (HO2S) at the right side of the steering gear.

Remove the wiring from the clips at the power steering line on the steering gear.

Remove

1. the screw for the wiring clamp at the bracket at the rear edge of the sub-frame
2. the lower screw that holds the heat deflector plate over the turbocharger (TC)
3. the three nuts that hold the front exhaust pipe to the turbocharger (TC).

Tie up the front exhaust pipe at the right suspension turret (cars without All-wheel drive (AWD)).

Removing the air conditioning aggregate

Disconnect the connector from the pressostat in the air conditioning (A/C) receiver drier.

Slacken off the lower right screw for the cooling unit.

Pull the cooling unit down. Carefully pull the wiring for the pressostat through the cavity at the mounting for the cooling unit.

Release the lower ventilation pipe for the control module box from the sub-frame.

Exposing the air conditioning (A/C) compressor

Remove the upper radiator hose.

Remove the auxiliaries belt.

Disconnect the one-pin connector for the compressor magnetic clutch.

Remove the four screws holding the air conditioning (A/C) compressor to the engine.

Tie up the compressor in the front cover plate.

Note. Handle the compressor carefully to make sure that there is no bending of the AC-pipes.

Expose the wiring for the front heated oxygen sensor (HO2S).

Disconnect the connector for the level sensor in the expansion tank.

Remove

1. the heat deflector plate above the turbocharger (TC)
2. the hoses for the heater unit at the terminal in the firewall
3. the bleed hose for the radiator at the expansion tank
4. the ABS line and clips and the power steering hose.

Lift up the power steering fluid reservoir and the expansion tank. Place them on top of engine.

Separating the steering shaft

Remove the ignition key.

Remove the screw from the joint between the steering gear and the steering shaft.

On one side, measure the length of the track rod in relation to the steering gear housing. Note the measurement.

Press up the joint from the steering gear.

Removing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)

Remove

1. the nuts where the exhaust pipe divides downstream of the three-way catalytic converter (TWC)
2. the screws securing the SIPS member to the bodywork.

Remove the brake pipe from the holders on the SIPS member.

Lift off the front exhaust pipe from the turbocharger (TC) and the rear system.

Lower and pull back the three-way catalytic converter (TWC) with the SIPS member.

Note. The routing of the heated oxygen sensor's cable harness over brake pipe.

Removing the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only)

remove the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only). See Pinion seal bevel gear, replacing .

Scheme 199

Use a post hoist with a lifting table and stud guides.

Position the lifting table against the sub-frame.

Note. Make sure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

Remove

1. the sub-frame brackets screws
2. the screws for the sub-frame.

Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.

Unhook the control arms from the ball joint pinion.

Hold the constant velocity joint. Pull the drive shaft off the hub. Let the drive shafts rest against the control arms.

Turn the engine block heater out of its position.

Check that the air conditioning (A/C) compressor is hanging free.

Continue lowering the engine and transmission unit.

See Engine/transmission, installing

See Engine/transmission, removing

Tool list

Special tools

9995562

9995462

9995488

9995474

9995722

9992810

9995185

9995464

9995428

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Remove

1. the battery negative cable. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
2. the expansion tank cap
3. the air pre-heating hose
4. the cross stay between the suspension turrets
5. 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 .

Only applies to B5244SG and B5244SG2

Drain the gas line acc. to Draining the gas pipe .

Drain the fuel system acc. to Draining the fuel system

Note. Protect the openings against dirt. Place the lines to one side. Make sure that all cleanliness conditions for working with the fuel injection system are followed.

Scheme 200

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

1. the right-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
2. the left-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
3. the screw for the lower torque rod in the transmission.

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

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

Scheme 201

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.

Scheme 202

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.

Note. The metal hose for the front exhaust pipe is damaged very easily. Therefore it should be handled with great care to avoid leakage later on.

Scheme 203

1. the connector from the mass air flow (MAF) unit
2. the connector from the air assisted control valve
3. the intake hose between the air cleaner housing and the front panel.
4. the intake hose from the air cleaner (ACL)
5. the vacuum hose for control of preheated air
6. the air cleaner assembly.
7. the braided ground cable between the engine and the cowl panel.
8. the heater hoses from the cowl panel
9. the brake vacuum hose from the intake manifold. Place it to one side.

Scheme 204

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

Scheme 205

Remove

1. the lower radiator hose
2. the ground lead on the transmission
3. the mechanical transmission cables. Mark up the cables
4. 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
5. the air filter bracket.

Applies to cars with automatic transmissions

Scheme 206

Remove

1. the lower radiator hose
2. the two oil cooling hoses for the transmission from the radiator
3. the ground lead on the transmission
4. the mechanical gear selector cable. Separate the terminal block at the bracket for the air filter
5. the air filter bracket.

Scheme 207

Remove

1. the upper radiator hose from the thermostat housing
2. the expansion tank
3. the auxiliaries belt
4. the three screws retaining the power steering pump.

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

Note. Leave the power steering pump in place for the moment.

Scheme 208

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.

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

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

Note. Do not touch the pins on the control module with fingers. Static electricity may damage components in the control module.

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.

Scheme 209

Lift up the power steering pump and put it to one side.

Use lifting yoke 9992810 .

Fit hook 9995185 between the engine's lifting lugs at the auxiliaries bracket and the upper torque rod bracket.

Fit lifting lug 9995464 in the exhaust manifold.

Fit mounting bracket 9995428 to the hooks and lifting lug.

Lift out the engine.

Remove the front engine pad when lifting.

Adjust the lift angle throughout the lift.

A relatively large angle is required.

Note. Check carefully that the drivetrain goes clear of the bodywork and any optional equipment. Also make sure that no engine or transmission wiring catches during the lift.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Reinstalling the engine and transmission

Use lifting yoke 9992810 , mounting bracket 9995428 , lifting lug 9995464 and two hooks 9995185 .

Align the lifting yoke so that the weight of the engine is evenly distributed.

Adjust the hoist angle throughout the lift.

Note. Check that the drivetrain goes clear of the bodywork and any optional equipment.

Tighten the nut of the front engine mounting.

Scheme 210

Install the engine and transmission wiring.

Plug in the engine and transmission wiring connectors to the connector plate.

Press the connector plate into place in the lower section of the control module box.

Install the intermediate section. Align the ventilation pipe at the rear edge of the control module box.

Screw the control module box into place in the fender liner.

Press the control modules down carefully.

Lock into place using mounting bracket 9995722 .

Press the cover into place.

Install

1. the air conditioning (A/C) compressor. Tighten to 25 Nm . Plug in the connector of the AC compressor's electromagnetic clutch.
2. the engine and transmission wiring in the mountings on the subframe.
3. the power steering pump. Tighten to 25 Nm .
4. the expansion tank and coolant hoses
5. the upper radiator hose
6. the auxiliaries belt

Applies to cars with manual transmissions

Install

1. the air filter bracket. Connect the terminal block at the bracket for the air filter
2. the ground lead on the transmission
3. the lower radiator hose
4. the rubber mounted mounting for the mechanical gear selector cables
5. the mechanical transmission cables.

Scheme 211

Connect the clutch cable. Use a new seal .

Note. Make sure that the clip locates in its channel.

Remove the lock grip pliers.

Bleed the clutch.

Applies to cars with automatic transmissions

Install

1. the air filter bracket Connect the terminal block at the bracket for the air filter
2. the ground lead on the transmission
3. the lower radiator hose
4. the two oil cooler pipes to the radiator
5. the mechanical transmission cable.

Remove radiator protection 9995474 .

Install

1. the engine cooling fan assembly with shroud.
2. the air cleaner (ACL) assembly
3. the canister purge (CP) valve in its bracket and connect the EVAP canister vacuum hose
4. the manifold absolute pressure (MAP) sensor to the mounting in the front cover plate
5. connect the engine cooling fan (FC) connectors. Clamp the wiring.

Install

1. the brake vacuum hose on the inlet pipe
2. the heater hoses on the cowl panel
3. the braided ground cable between the engine and cowl panel.

1. the air cleaner (ACL) assembly
2. the air preheating hose
3. the vacuum hose for control of preheated air
4. the intake hose between the air cleaner (ACL) housing and the front panel
5. the inlet hose between the air cleaner (ACL) and the throttle body (TB).

Connect the connector for the HFM unit and the assisted air control valve.

Scheme 212

Install

1. the front and rear screws for the engine mountings (A). Tighten to 50 Nm .
2. the screw for the torque rod in the transmission. Use a new screw and nut. Tighten the screws. Tighten to 35 Nm . Angle-tighten 90° .
3. both the screws for the right engine mounting (B). First bend the right fender liner slightly so that it is out of the way.

Lubricate the studs at the manifold. Use paste (P/N 116 14 08 ). Avoid skin contact with the paste.

Install

1. the front exhaust pipe on the manifold. Use a new gasket and new nuts . Do not tighten.
2. the screws securing the SIPS member to the bodywork
3. the brake pipe in the holders at the SIPS member Tighten the nuts where the manifold and the front exhaust pipe separate. Tighten the screws securing the SIPS member. Tighten to 25 Nm . Secure the wiring for the heated oxygen sensors (HO2S) at the rear engine mounting and at the steering gear
4. the right-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
5. the left-hand drive shaft. See «Drive shaft left, replacing»(ref-445723-S24390762452012010600000)
6. the wheels. See «Installing wheels»(ref-415307-S16574462602011081500000) .

Install the engine positive cable on the terminal at the left suspension turret.

Install the support brace between the suspension turrets. Tighten the screws at the suspension turrets. Tighten to 50 Nm . Tighten the engine bracket screw. Tighten to 80 Nm .

Top up the coolant. Coolant volume approximately: 7 liters .

Connect the negative battery cable. First read Battery, disconnecting .

Fill with engine oil. Oil volume including filter: 5.8 liters .

Scheme 213

Check the function

1. Connect a VIDA station.
2. Start the engine and run it until the thermostat opens.
3. Read off any diagnostic trouble codes (DTCs)
4. Check sealing.
5. Check and if necessary adjust the oil and coolant levels
6. Wipe clean.

Automatic transmissions: Check the transmission fluid level.

Engine/transmission, removing/installing

See Engine/transmission, removing/installing

See Engine/transmission, installing

See Engine/transmission, removing

Special tools

9512050

9995972

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.

Note. For tightening torques, see: Tightening torque .

Note. To ensure that there is no exhaust leakage, see: Flanged joint, assembling .

Installing the engine and transmission unit

Raise the engine and the transmission unit. Use a lifting table with locating pins.

Stop when the sub-frame is approximately 15 cm below the frame members.

Install (left and right-hand sides)

1. the drive shaft to the hub. Install the center screws. Do not tighten yet.
2. the ball joint to the control arm. Install the nuts. Do not tighten yet. NOTE: Make sure that the contact faces on the ball joints and link arms are clean.

Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.

Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.

Align the steering shaft joint with the hole in the firewall.

Lift the engine and transmission unit up to the frame members.

Note. Make sure that no hoses, wiring, or anything else catches.

Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.

Use new screws. Lube the screws with oil.

Tighten, see: Summary of specific components and tightening torques .

First tighten the screws on the sub-frame's left side, then on the right.

Tighten the screws for the brackets M10.

Remove the lifting table.

Install a new screw on the steering shaft joint. Torque tighten.

Connecting fuel lines

Connect the quick-release connectors and fuel line to the engine and engine block heater (option). Press the EVAP line together at the rubber joint. See also: Fuel system, quick-release connectors .

Installing the propeller shaft

Install the propeller shaft. See Propeller shaft, replacing .

Installing the three-way catalytic converter (TWC)

Install the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing .

Scheme 214

Install

1. the tie rods. Use new nuts
2. the link rod to the anti-roll bar. Use new nuts. Counterhold using Torx 27
3. the bracket for the brake pipe to the body. Tighten
4. the ball joint nut and the control arm. Tighten. Counterhold using Torx40
5. the center screw for the drive shaft. Tighten.

Install

1. the lower engine splash guard, only applies to cars with automatic transmissions
2. the front wheels. See «Installing wheels»(ref-415307-S16574462602011081500000)

Installing the air conditioning (A/C) compressor

Note. Handle the compressor carefully to make sure that there are no kinks in the AC-pipes.

Install the 4 screws while the compressor is loose.

Raise the compressor and screw it into place.

Connect the one-pin connector to the compressor magnetic clutch.

Installing the connector

Install

1. the connector on the pressostat in the air conditioning (A/C) receiver drier
2. the cable in the clips and the clamps on the fan shroud
3. the connectors for the pressure and temperature sensors on the charge air cooler (CAC).

Connect the engine cable to the control module box.

Install

1. the ground lead to the ground terminal at the right fender edge in the engine compartment
2. the auxiliaries belt
3. the intermediate piece for the control module box
4. the control modules. See «Engine control module (ECM), replacing»(ref-415281-S12652924142011081500000)
5. the cover for the control module box
6. expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
7. servo oil reservoir. Check that the hoses are correctly positioned.

Clamp the ABS cable to the power steering hose.

Scheme 215

Applies to cars with manual transmissions.

Install

1. the pipe junction
2. the clutch pipe in the junction. Use a new seal. Ensure that the clip locates in its channel. Remove the hose clip
3. the transmission cables.

Bleed the clutch.

Use Volvo Genuine parts brake fluid.

Applies to automatic transmissions.

Install

1. the transmission cable
2. the oil cooler hoses. Remove the seals.

Install

1. the hoses for the heater unit at the terminal in the firewall
2. the lower and upper coolant hoses for the engine
3. the rubber hose on the charge air pipe on the intake for the charge air cooler (CAC)
4. the dip stick pipe
5. the brake vacuum hose to the intake
6. the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Tighten both the clamps.

HINT: Use a hot air gun to facilitate installation.

Install

1. the connector for the engine cable to the central electrical unit
2. the positive lead for the starter motor to the terminal block
3. the cover over the central electrical unit
4. the ground lead between the engine and body in the front frame member.

Install

1. the ground strip at the top/rear of the cylinder head
2. the charge air cooler pipe over the engine
3. the inlet hose for the turbocharger (TC) to the air cleaner (ACL)
4. air cleaner (ACL) assembly
5. the mass air flow (MAF) sensor connector. Tighten the hose clamps
6. the turbocharger control valve on the air cleaner (ACL)
7. the intake pipe between the front cover plate and the air cleaner (ACL)
8. the engine stabilizer brace between the suspension turrets
9. the negative battery cable. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000) .

Install

1. coolant
2. engine oil
3. power steering fluid.

Start the engine.

Warm up the engine until the thermostat opens.

Check for leakage.

Check the oil and coolant levels. Adjust if necessary.

Check the transmission oil level (automatic transmissions only). Top up if necessary.

Special tools

9995666

9995722

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Remove

1. the battery negative lead. First read «Battery, disconnecting»(ref-415278-S03862267492011081500000)
2. the cross stay between the suspension turrets
3. the turbocharger control valve from the air cleaner (ACL). Disconnect the connector for the mass air flow (MAF) sensor. Slacken off the hose clamp on the mass air flow (MAF) sensor
4. mass air flow (MAF) sensor connector
5. the brake vacuum hose from the air cleaner (ACL)
6. the air cleaner (ACL) assembly. Seal the openings in the intake pipe for the turbocharger (TC)
7. the plastic charge air pipe above the engine. Seal the opening in the turbocharger (TC)
8. the ground strip at the top/rear of the cylinder head.

Removing components around expansion tank

Disconnect the connector for the level sensor in the expansion tank.

Remove

1. the hoses for the heater unit at the terminal in the firewall
2. the bleed hose for the radiator at the expansion tank
3. the ABS line and clips from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.

Remove

1. control module unit cover
2. the control modules. Use brace «9995722»(ref-403953-S10522720692011061000000)
3. the surround for the control module box.

Scheme 216

Remove

1. the red retaining clip for the connector using a screwdriver
2. the connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver.

Lift up the connector with the protection underneath and put it to one side.

Remove the ground lead from the right-hand fender liner. Slide out the wiring between the front cover plate and the air conditioning (A/C) pipe.

Remove the upper radiator hose.

Remove the auxiliaries belt.

Disconnect the one-pin connector for the compressor magnetic clutch.

Remove the four screws holding the air conditioning (A/C) compressor to the engine. Tie up the compressor in the front cover plate.

Remove the ignition key.

Raise the car.

Remove

1. the left and right front wheels
2. the splash guard under the engine
3. the splash guard under the engine (Only applies to cars with automatic transmissions).

Remove the screw from the joint between the steering gear and the steering shaft.

Remove the nut on the tie rod from the wheel spindle (on the left and right-hand sides).

On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement. Press up the joint from the steering gear.

Scheme 217

Disconnect the ABS line from the mounting in the spring strut.

Remove

1. the screw for the drive shaft using a screwdriver in the brake disc vents
2. the link from the anti-roll bar
3. the nut for the ball joint and link arm. Clean the exposed threads outside the nut. Spray using rust solvent before removing the nut.

Note. Counterhold with a Torx TX 40 in the ball joint top when removing the nut. This is so that the ball joint gaiter does not turn.

Note. If an engine heater is installed, mark up the fuel lines.

Separate the quick-release connectors for the fuel pressure line and engine block heater (option).

HINT: Use tool 9995666 .

Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.

Removing the three-way catalytic converter (TWC)

Remove the three-way catalytic converter (TWC). See Three-way catalytic converter (TWC), replacing .

Removing the propeller shaft

Remove the propeller shaft. See Propeller shaft, replacing .

Lowering the engine and transmission

Use a post hoist with a lifting table and stud guides. Anchor the lifting table against the sub-frame.

Note. Make sure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

Scheme 218

Remove

1. the screws for the sub-frame brackets
2. the screws for the sub-frame. Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.

Unhook the control arms from the ball joint pinion.

Hold the constant velocity joint. Pull the drive shaft off the hub.

Let the drive shafts rest against the control arms.

Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and transmission unit.

Removing the engine coolant heater (option)

Remove

1. the bumper cover on the left hand side. Use a weatherstrip tool
2. the M8 nut at the top of the left-hand fender liner for the engine coolant heater
3. the connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.

Remove

1. the screws for the sub-frame brackets
2. the screws for the sub-frame. Lower the engine and transmission approximately 15 cm so that the drive shafts describe a horizontal line between the hub and transmission.

Unhook the control arms from the ball joint pinion.

Hold the constant velocity joint. Pull the drive shaft off the hub.

Let the drive shafts rest against the control arms.

Turn the engine block heater out of its position.

Check that the air conditioning (A/C) compressor is hanging free. Continue lowering the engine and transmission unit.

Engine block, installing components

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Note. For tightening torques, see Tightening torque .

Installing the components for the engine pad

1. the thermostat housing
2. knock sensor (KS)
3. flame trap
4. the pipe screw for the water-heated crankcase ventilation.

If in doubt about the order of assembly, see Engine body, exposing .

Scheme 219

The direction of the ignition coil and the wiring routing is illustrated.

Installing the flywheel and carrier plate

Install the flywheel. See: Flywheel .

Install the carrier plate. See: Replacing the carrier plate .

Engine body, exposing

Special tools

9989721

9992520

9995112

9995297

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

HINT: Remove the lower screws (these are difficult to access) between the transmission and engine before removing the engine and transmission unit. The engine and transmission unit must be placed on a suitable surface.

HINT: Take the weight off the transmission. Remove the remaining screws. Carefully remove the transmission.

Remove the clutch. See Pressure plate/clutch driven plate, replacing .

Remove the flywheel sensor.

Install gear sector 9995112 .

Remove all screws except for the uppermost screw which secures the flywheel to the crankshaft. Slacken off the uppermost screw. Leave it in place, screwed in a few turns.

Carefully work the flywheel and carrier plate loose. If necessary, use 2 groove-cut chisels. Apply these between the cylinder block and the flywheel and carrier plate.

Hold the flywheel and carrier plate and remove the final screw.

Install the engine in a stand

Use mounting stand 9992520 , fixture 9995297 and screw set 9989721 .

Scheme 220

Scheme 221

See Engine/transmission, installing

See Engine/transmission, removing

See Engine/transmission, installing

See Engine/transmission, removing

See Engine/transmission, installing

See Engine/transmission, removing

Oil pan, replacing

Special tools

9512767

Note. As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 222

Remove

1. the oil dipstick and pipe
2. the splashguard under the engine.

Drain the engine oil and remove the oil filter.

Release the oil cooler from the pan. Hang up at the rear.

Remove the screw from the bracket for the fuel line.

Disconnect the connector for the oil level sensor.

Removing the oil pan

Slacken off all the screws holding the oil pan.

Remove all but four screws. It is recommended that the four screws in the corners of the pan are left in place.

Carefully tap the pan using a rubber mallet until the joint and its liquid gasket releases.

Remove the four remaining screws.

Remove the pan.

Note. For tightening torques, see Tightening torque .

Clean the gasket surfaces on the oil pan and cylinder block. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Scheme 223

Apply liquid gasket 1161 059-9 to the oil pan. Use roller 9512767 .

Install

1. new O-rings
2. the Oil pan. Secure the Oil pan loosely using a few screws
3. the remaining screws loosely.

Scheme 224

Press the oil pan towards the transmission. Tighten the screws (1), (2), (3) and (4). See Summary of specific components and tightening torques . Tighten the screws (5). See Summary of specific components and tightening torques .

Tighten all screws in the screwed oil pan joint. Start at the transmission and continue forwards in pairs.

Install the screw for the bracket for the fuel line.

Connect the oil cooler to the pan. Use new O-rings . Reinstall the pipe on the sub-frame.

Install

1. a new oil filter
2. the oil plug with a new gasket
3. the oil dipstick and its pipe. Use a new O-ring. NOTE: Check that the O-ring is correctly positioned.

Fill with engine oil. Run the engine to operating temperature.

Check for oil leaks from the oil pan or oil cooler.

Install the splashguard under the engine.

Check the oil level. Top up if required.

See Oil pan, replacing

See Oil pan, replacing

Remove

1. the oil dipstick and its pipe.
2. the splashguard under the engine.

Drain the engine oil and remove the oil filter.

Release the oil cooler from the sump. Hang up at the rear.

Remove the screw from the bracket for the fuel line.

Removing the oil sump

Slacken off all screws holding the oil sump.

Remove all screw except for four. It is recommended that the four screws in the corners of the sump are left in place.

Carefully tap the sump with a rubber mallet until the joint and its liquid gasket releases.

Remove the four remaining screws.

Remove the sump.

Clean the gasket surfaces on the oil sump and cylinder block. Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440.

Installing the oil pan

Apply liquid gasket 1161 059-9 to the sump. Use roller 9512767 .

Install

1. new O-rings.
2. the oil sump. Secure it loosely with a few screws.
3. the remaining screws loosely.

Press the sump against the transmission. Tighten the screws (1), (2), (3) and (4) to 3 Nm . First tighten the screws (5) to 25 Nm . Then tighten to 48 Nm .

Tighten all screws in the sump joint to 17 Nm. Start at the transmission and continue forwards in pairs.

Install the screw for the bracket for the fuel line.

Connect the oil cooler to the sump. Use new O-rings. Reinstall the pipe on the sub-frame.

Install

1. a new oil filter.
2. the oil plug with a new gasket.
3. the oil dipstick and its pipe. Use a new O-ring. NOTE: Check that the O-ring is correctly positioned.

Fill with engine oil. Run the engine to operating temperature.

Check for oil leaks from the oil sump or oil cooler.

Install the splashguard under the engine.

Check the oil level. Top up if required.

Auxiliaries belt / belt tensioner, replacing

Special tools

9995722

9997109

Note. The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Scheme 225

Ignition off. Wait 2 minutes.