Section 59 (Engine - Removal, Replacement And Installation)
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- Crank Mechanism
- Crank Mechanism (B5234T3, Aw55-50/51SN; 2001-2004)
- Crank Mechanism (B5234T3, M56; B5244T3, M56; 2002)
- Crank Mechanism (B5234T3, M56; 2003-2004)
- Crank Mechanism (B5234T3, M56; B5244T3, M56; 2001)
- Crank Mechanism (B5244S, Aw55-50/51SN; 2001-2007)
- Crank Mechanism (B5244S, M56; 2002)
- Crank Mechanism (B5244S, M56; 2001)
- Crank Mechanism (B5244S, M56; 2003-2007)
- Crank Mechanism (B5244S6; 2003-2006)
- Crank Mechanism (B5244T3, Aw50/51 AWD; 2001-2002)
- Crank Mechanism (B5244T3, Aw55-50/51SN; 2001-2003)
- Crank Mechanism (B5244T3, M56; 2003)
- Crank Mechanism (B5244T5, Aw55-50/51SN; 2005-2007)
- Crank Mechanism (B5244T5, M66; 2005-2007)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2005-2007)
- Crank Mechanism (B5254T2, Aw50/51 AWD; 2003-2004)
- Crank Mechanism (B5254T2, Aw55-50/51SN; 2004)
- Crank Mechanism (B5254T2, M56; 2004)
- Crank Mechanism (B5254T2, M56; 2005-2007)
- Crank Mechanism (B5254T4, Aw50/51 AWD; 2004-2006)
- Crank Mechanism (B5254T4, M66 AWD; 2004-2007)
- Crank Mechanism (B5254T4, TF-80SC AWD; 2006-2007)
- Cylinder Head
- Cylinder Head (B5234T3; B5244T3; 2001-2002)
- Cylinder head/gasket, replacing
- Notes
- Removing the cylinder head gasket
- Preparation
- Draining coolant
- Removing components
- Draining the fuel line
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Cylinder head gasket, installing
- Tightening torque
- Setting up the engine
- Installing the cylinder head
- Installing tappets and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Variable valve timing unit, checking and adjusting
- Installing components
- Installing the intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5234T3; 2003-2004)
- Cylinder head/gasket, replacement
- Notes
- Removal
- Preparation
- Draining coolant
- Removing components
- Depressurizing the fuel system
- Removing the fuel rail
- Removing ignition coils
- Removing intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Installation
- Notes
- Cleaning
- Setting up the engine
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Checking and adjusting the variable valve timing unit
- Installing components
- Installing intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacement
- Cylinder Head (B5244S; 2001-2007)
- Cylinder head/gasket, replacing
- Notes
- Removal
- Preparation
- Draining the coolant
- Separating the exhaust system
- Removing components
- Draining the fuel line
- Removing the fuel rail
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Installing the cylinder head
- Notes
- Tightening torques
- Aligning the crankshaft
- When replacing or working on the cylinder head
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the intake pipe for the coolant pump
- Installing the rear camshaft seal
- Installing the front camshaft seal
- Checking and adjusting the variable valve timing unit
- Installing components
- Installing the intake manifold and gasket
- Installing the fuel and air distribution pipe
- Assembling the exhaust system
- Finishing
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5244S6; 2003-2006)
- Cylinder head/gasket, replacing
- Notes
- Removal
- Preparation
- Removing the three-way catalytic converter (TWC)
- Draining the coolant
- Removing components
- Draining the fuel line
- Removing the intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Releasing the inlet pipe for the coolant pump
- Removing the camshaft cover and cylinder head
- When replacing or working on the cylinder head
- Cleaning
- Installing the cylinder head
- Notes
- Tightening torques
- Aligning the crankshaft
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft covers
- Installing the intake pipe for the coolant pump
- Installing the rear camshaft seal
- Installing the front camshaft seal
- Checking and adjusting
- Installing components
- Installing the intake manifold and gasket
- Installing the fuel and air distribution pipe
- Installing the exhaust manifold
- Finishing
- Check
- Cylinder head/gasket, replacing
- Cylinder Head (B5244T3; 2003)
- Cylinder Head (B5244T5; 2005-2007)
- Cylinder head/gasket, replacement
- Notes
- Removal
- Preparation
- Draining coolant
- Removing components
- Draining the fuel system
- Removing the fuel rail
- Removing ignition coils
- Removing intake manifold
- Setting up the engine
- Removing the timing belt
- Removing the timing gear pulley
- Removing components from turbocharger (TC)
- Releasing the coolant pump inlet pipe
- Removing the camshaft cover and cylinder head
- When replacing/machining the cylinder head
- Installation
- Notes
- Cleaning
- Setting up the engine
- Installing the cylinder head
- Installing valve lifters and camshafts
- Applying liquid gasket
- Installing the camshaft cover
- Installing the manifold and turbocharger (TC)
- Installing the rear camshaft seal
- Installing the front camshaft seals
- Checking crankshaft setting
- Installing VVT-unit/timing gear pulley on exhaust camshaft
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing components
- Installing intake manifold
- Installing the fuel rail
- Check
- Cylinder head/gasket, replacement
- Cylinder Head (B5254T2; 2003-2007)
- Cylinder Head (B5254T4; 2004-2007)
- Cylinder Head (B5254T4, TF-80SC AWD; 2006-2007)
- Cylinder Head (B5234T3; B5244T3; 2001-2002)
- Engine Mounting
- Engine Mounting (2001-2007)
- Engine Mounting (B5234T3; 2001-2004)
- Engine Mounting (B5234T3, Aw55-50/51SN; B5234T3, M56; 2001-2004)
- Bushing sub-frame, replacing
- Notes
- Important information
- Preparation
- Removing components
- Removing the front engine pad lower screw
- Removing the nuts for the lower torque rod
- Folding out the fender liner
- Removing the screws for the right-hand engine mounting
- Removing the nuts and screw for the steering gear
- Removing the delivery line for the steering gear
- Lowering the sub-frame
- Pressing out the bushings
- Installing the bracket for the heated oxygen sensor (HO2S)
- Marking for the bushing on the sub-frame
- Marking the left-hand rear bushing
- Pressing in the bushings
- Lifting the sub-frame
- Installing the nuts and screw for the steering gear
- Installing the delivery line from the steering gear
- Installing the screws for the engine mounting to the engine
- Installing the protective plate
- Installing the screw for the front engine pad
- Tightening the nuts for the lower torque rod
- Installing the air intake cover
- Installing the protective cover
- Removing the lifting tools
- Engine mount rear, replacing
- Bushing sub-frame, replacing
- Engine Mounting (B5244S; 2001-2007)
- Engine Mounting (B5244S, Aw55-50/51SN; B5244S, M56; 2001-2007)
- Engine Mounting (B5244S6; 2003-2006)
- Engine Mounting (B5244T3; 2001-2003)
- Engine Mounting (B5244T3, Aw50/51 AWD; 2001-2002)
- Engine Mounting (B5244T3, Aw55-50/51SN; B5244T3, M56; 2001-2003)
- Engine Mounting (B5244T5; 2005-2007)
- Engine Mounting (B5244T5, Aw55-50/51SN; B5244T5, M66; 2005-2007)
- Engine Mounting (B5254T2; 2003-2007)
- Engine Mounting (B5254T2, Aw50/51 AWD; 2003-2007)
- Engine Mounting (B5254T2, Aw55-50/51SN; B5254T2, M56; 2004-2007)
- Engine Mounting (B5254T4; 2004-2007)
- Engine Mounting (B5254T4, Aw50/51 AWD; 2004-2006)
- Engine Mounting (B5254T4, M66 AWD; 2004-2007)
- Engine Mounting (B5254T4, TF-80SC AWD; 2006-2007)
- Engine/Transmission
- Engine/Transmission (B5234T3; 2001-2004)
- Engine/transmission, installing
- Notes
- Installing the engine and transmission unit
- Installing the propeller shaft (all-wheel drive (AWD) only)
- Installing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
- Installing the front exhaust pipe
- Connecting fuel lines
- Assembling the spring strut
- Cars with engine block heaters (option)
- Installing the air conditioning (A/C) compressor
- Installing components
- Installing the transmission cable
- Installing the engine coolant fan (FC)
- Finishing
- Final check
- Engine/transmission, removing
- Notes
- Preparation
- Removing the engine cooling fan (FC)
- Removing the transmission cable
- Draining the fuel line
- Removing components
- Draining coolant
- Cars with engine block heaters (option)
- Preparations for removal of the drive shafts
- Separating the fuel line
- Separating the front exhaust pipe
- Removing the air conditioning aggregate
- Exposing the air conditioning (A/C) compressor
- Separating the steering shaft
- Removing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
- Removing the propeller shaft from the transmission and drive distribution box (all-wheel drive (AWD) only)
- Lowering the engine and transmission
- Engine/transmission, installing
- Engine/Transmission (B5244S; 2001-2007)
- Engine/Transmission (B5244S6; 2003-2006)
- Engine/Transmission (B5244T3; 2001-2003)
- Engine/Transmission (B5244T5; 2005-2007)
- Engine/transmission, installing
- Notes
- Installing the engine and transmission unit
- Connecting fuel lines
- Installing the propeller shaft
- Installing the three-way catalytic converter (TWC)
- Assembling the spring strut
- Installing the air conditioning (A/C) compressor
- Installing the connector
- Installing components
- Installing components on the transmission
- Final check
- Engine/transmission, removing
- Notes
- Preparation
- Draining coolant
- Draining the fuel system
- Removing components from the transmission
- Removing the mechanical transmission cables from the transmission
- Removing components
- Removing the connector with cable and cable protector
- Exposing the air conditioning (A/C) compressor
- Separating the steering shaft
- Removing front suspension components (both sides)
- Separating the fuel line
- Removing the three-way catalytic converter (TWC)
- Removing the propeller shaft
- Lowering the engine and transmission
- Removing the engine coolant heater (option)
- Engine/transmission, installing
- Engine/Transmission (B5254T2; 2003-2007)
- Engine/Transmission (B5254T4; 2004-2007)
- Engine/Transmission (B5254T4, TF-80SC AWD; 2006-2007)
- Engine/Transmission (B5234T3; 2001-2004)
- Engine Block Components (B5244T5; 2005-2007)
- Oil Pan
- Oil Sump
- Timing Gear
- Timing Gear (B5234T3; B5244T3; 2001)
- Timing Gear (B5234T3; 2002-2004)
- Timing Gear (B5244S; 2002)
- Timing Gear (B5244S6; 2003-2006)
- Timing Gear (B5244T3; 2002-2003)
- Timing Gear (B5244T5; B5254T2; 2005-2007)
- Timing Gear (B5254T2; 2003-2004)
- Timing Gear (B5254T4; 2004-2007)
- Auxiliaries belt / belt tensioner, replacing
- Camshaft seal/variable valve timing (VVT) unit, replacing
- Notes
- Removal
- Installation
- Notes
- Cleaning
- Installing the front camshaft seal
- Installing the crankshaft adjustment tool
- Aligning the crankshaft
- Installing the variable valve timing (VVT) unit on the exhaust camshaft
- Installing the variable valve timing (VVT) unit on the intake camshaft
- Finishing
- Installing the timing belt
- Adjusting the timing belt
- Checking the markings and belt tension
- Installing components
- Checking the engine
- Rear camshaft seal
- Timing belt, replacing
- Variable valve timing solenoid, replacing
- Transmission