Contents: Removal ⬇ Installation ⬇
Removal
Note: All disconnected wiring harnesses and hoses must be reconnected to their original positions.
1. Disconnect the wiring harness connectors (1) and (2) from the holder, then disconnect the wiring harness connectors and release the wires from the clips.
For models with ACT system
2. Disconnect the wiring harness connectors (4) from the No. 3 cylinder exhaust camshaft adjuster (1) and the No. 3 cylinder intake camshaft adjuster (2), as shown in the figure below.
3. Disconnect the hose between the ventilation breather (5) and the air filter housing (3).
Continued for all models
4. Unscrew the mounting screws (arrows) from the camshaft housing, as shown in the figure below.
5. Unscrew the mounting screws (arrows) shown in the figure below.
6. Lift the cooling system pipes and remove the thermal insulation coating (1).
7. Remove the soundproofing coating.
8. Disconnect the wiring harness connector (1) from the engine oil level and temperature sensor as shown in the figure below.
9. Mark the position of the clamp relative to the elements being connected, as shown in the figure below.
10. Unscrew the fastening screw (2) and remove the fastening clamp shown in the figure below.
11. Unscrew the mounting screws (1) and mounting nuts (arrows) shown in the figure below.
12. Unscrew the fastening screws (1) and remove the heat-insulating coating of the right drive shaft, as shown in the figure below.
13. Unscrew the mounting bolts and remove the intermediate cross member shown in the figure below.
14. Loosen the mounting clamp (arrow) shown in the figure below, then move it towards the rear of the body.
15. Unscrew the mounting bolts (arrows) shown in the figure below.
16. Release the wiring harness connector from the holder, then disconnect the connector from the oxygen sensor. Release the wiring harness from the clips.
17. Disconnect the cardan shaft (1) from the angular transmission, as shown in the figure below (for more details, see the relevant section in the chapter Drive shafts).
18. Install the special support tool T10533 (A) as shown in the figure below.
19. Screw the original crossmember mounting screw into the front threaded hole to secure the special tool.
20. Screw the M8x40 screw with a washer into the left threaded hole.
21. Tighten the bolts by hand.
22. Move the power unit assembly forward as far as possible.
23. Unscrew the mounting screws (the arrows shown in the figure below).
24. Move the cardan shaft (1) in the direction of the arrow as shown in the figure below.
25. Remove the catalytic converter from the rear.
Note: The outlet bellows should not be bent more than 10°, as there is a high probability of
17. Disconnect the cardan shaft (1) from the angular transmission, as shown in the figure below (for more details, see the relevant section in the chapter Drive shafts).
18. Install the special support tool T10533 (A) as shown in the figure below.
19. Screw the original crossmember mounting screw into the front threaded hole to secure the special tool. 20. Screw the M8x40 screw with a washer into the left threaded hole.
21. Tighten the bolts by hand.
22.Move the power unit assembly forward as far as possible.
23. Unscrew the mounting screws (the arrows shown in the figure below).
24. Move the cardan shaft (1) in the direction of the arrow as shown in the figure below.
25. Remove the catalytic converter from the rear.
Note:
- The outlet pipe bellows should not be bent more than 10°, as there is a high risk of damage.
- Be extremely careful not to damage the metal mesh of the bellows.
26. Insert a flat-head screwdriver (2) into the recess (arrow) of the turbocharger housing and, using a lever motion, remove the sealing ring (1), as shown in the figure below.
Installation
Installation is carried out in the reverse order of removal.
Note:
- Self-locking nuts and gaskets must always be replaced after disassembly.
- Lubricate the bolts and screws that secure the catalytic converter with a special heat-resistant grease.
- Install the catalytic converter. To do this you need to:
| Approach | Action | Tightening torque |
| 1 | Install the catalytic converter onto the turbocharger and slightly tighten the mounting clamp shown in the figure below (arrow) | - |
| 2 | Tighten the mounting screws (3) and (5) and the mounting nuts (1), (2) and (4) by hand. | At this stage it should be possible to move the catalytic converter |
| 3 | Tighten the mounting clamp (arrow) | 15 Nm |
| 4 | Tighten the mounting screws and nuts in sequence 1...5 | 20 Nm |
