Engine - Removal, Replacement And Installation
- Crank Mechanism (1999-2005)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2004)
- Crank Mechanism (B5254T2, Aw50/51 AWD; B5254T2, Aw55-50/51SN; 2005-2006)
- Crank Mechanism (B6284T, 4T65EV-Gt; B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000-2001)
- Crank Mechanism (B6284T, 4T65EV-Gt; B6304S3, 4T65EV; 1999)
- Crank Mechanism (B6294S2; B6294T; 2002-2006)
- Cylinder Head (B5254T2; 2004-2006)
- 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 (B6284T; 1999)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing Components From Turbo 1
- Removing Components From Turbo 2
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Compressing The Tensioner / Damping Unit
- Removing The Timing Gear Pulley
- Removal Of Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold And Turbo 2
- Installing The Manifold And Turbo 1
- Installing Components At Turbo 1
- Installing Components At Turbo 2
- Exhaust System Assembly
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6284T; 2000-2001)
- Cylinder Head/Gasket, Replacement
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing Components From Turbo 1
- Removing Components From Turbo 2
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing the cylinder head gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold/Turbo 2
- Installing The Manifold/Turbo 1
- Installing Components To Turbo 1
- Installing Components To Turbo 2
- Exhaust System Assembly
- Checking And Filling Media
- Cylinder Head/Gasket, Replacement
- Cylinder Head (B6294S; 2000-2001)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing The Manifold
- Releasing The Inlet Pipe For The Coolant Pump
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover And Cylinder Head
- When Replacing Or Working On The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Intake Pipe For The Coolant Pump
- Installing The Manifold
- Installing Components
- Assembling The Exhaust System
- Checking And Filling Media
- Variable Valve Timing Unit, Checking And Adjusting
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6294S2; 2002-2006)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head/Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Removing The Manifold
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold
- Installing Components
- Installing The Exhaust System
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Cylinder Head (B6294T; 2002-2006)
- Cylinder Head/Gasket, Replacement
- Notes
- Removing The Cylinder Head / Gasket
- Notes
- Preparation
- Draining Coolant
- Removing Components
- Removing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe
- Removing The Turbocharger (TC)
- Draining The Fuel Line
- Removing The Fuel Rail
- Releasing The Inlet Pipe For The Coolant Pump
- Setting Up The Engine
- Removing The Timing Belt
- Removing The Variable Valve Timing Unit / Timing Gear Pulley
- Removing The Thermostat Housing
- Removing The Camshaft Cover And Cylinder Head
- When Replacing Or Working On The Cylinder Head
- Cleaning
- Installing The Cylinder Head / Gasket
- Notes
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing The Thermostat Housing
- Checking The Tensioner Pulley And Idler Pulley
- Checking The Variable Valve Timing (VVT) Unit
- Installing Components
- Installing The Fuel Rail
- Installing The Intake Pipe For The Coolant Pump
- Installing The Turbocharger (TC)
- Finishing
- Installing Three-Way Catalytic Converters (TWC) / Front Exhaust Pipe
- Installing The Drive Shaft
- Checking And Filling Media
- Cylinder Head/Gasket, Replacement
- Cylinder Head (B6304S3; 1999)
- Cylinder Head/Gasket, Replacing
- Notes
- Removing The Cylinder Head Gasket
- Notes
- Preparation
- Draining Coolant
- Separating The Exhaust System
- Removing Components
- Draining The Fuel Line
- Removing The Fuel Rail
- Removing The Manifold
- Releasing The Coolant Pump Inlet Pipe
- Setting Up The Engine
- Compressing The Tensioner / Damping Unit
- Removing The Timing Gear Pulley
- Removal Of Thermostat Housing
- Removing The Camshaft Cover/Cylinder Head
- When Replacing/Machining The Cylinder Head
- Cleaning
- Installing The Cylinder Head Gasket
- Notes
- Tightening
- Aligning The Crankshaft
- Installing The Cylinder Head
- Installing Valve Lifters And Camshafts
- Applying Liquid Gasket
- Installing The Camshaft Covers
- Installing The Rear Camshaft Seal
- Securing The Camshafts
- Installing The Front Camshaft Seal
- Installing Thermostat Housing
- Checking The Variable Valve Timing (VVT) Unit
- Installing The Coolant Pump Intake Pipe
- Installing The Manifold
- Installing Components
- Assembling The Exhaust System
- Checking And Filling Media
- Cylinder Head/Gasket, Replacing
- Drive Train (B6284T; 2000-2001)
- Drive Train (B6284T; 1999)
- Drive Train (B6294S2; 2002-2006)
- Engine Mounting (1999-2006)
- Bushing Sub-Frame, Replacing
- Overview
- Notes
- Important Information
- Preparation
- Removing The Charge Air Pipe And Hose (6-Cylinder Turbocharged Engines Only)
- Removing The Spark Plug Cover (6-Cylinder Engines Only)
- Installing The Lifting Eyelet (6-Cylinder Engines Only)
- 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 Vibration Damper (6-Cylinder Engines Only)
- Removing The Screws For The Right-Hand Engine Mounting (6-Cylinder Engines)
- 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
- Marking For The Bushing On The Sub-Frame
- Marking The Left-Hand Rear Bushing
- Pressing In The Bushings
- Installing The Wiring For The Heated Oxygen Sensor (HO2S)
- 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 Vibration Damper (6-Cylinder Engines Only)
- 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
- Removing The Lifting Lug And The Lifting Hook From The Engine And The Car (6- Cylinder Engines Only)
- Installing All Charge Air Pipes (Only 6-Cylinder Turbo Engines)
- Bushing Sub-Frame, Replacing
- Engine Mounting (B6284T; 1999-2001)
- Engine Mounting (B6294S; 2000-2001)
- Engine Mounting (B6294S2; B6294T; 2002-2006)
- Engine Mounting (B6304S3; 1999)
- Variable Valve Timing & Timing Belt (B6294S; 2000-2001)
- Variable Valve Timing & Timing Belt (B6304S3; 1999)
- Transmission (B5254T2; 2004-2006)
- 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
- Transmission, Installation
- Notes
- Cleaning And Lubricating The Input Shaft
- Checking Before Installing
- Adjusting The Position Of The Transmission And Engine
- Installing And Tightening Screws For The Transmission
- Lifting The Engine And Transmission To The Horizontal Position
- Installing The Rear Engine Mounting
- Installing The Bevel Gear
- Installing The Front Propeller Shaft (Applies to AWD)
- Fitting The Sub-Frame To The Body
- Installing The Sealing Ring For The CV Joint Housing
- Installing The Left Hand Drive Shaft To The Transmission, Wheel Spindle And Link Arm
- Installing New Lock Nuts And Screws On The Steering Gear
- Installing The Screw In The Rear Engine Pad
- Installing Screws For The Bracket For The Heated Oxygen Sensor (HO2S) Wiring
- Installing The Crossmembers
- Installing The Right-Hand Drive Shaft To The Gearbox, Wheel Spindle And Link Arm
- Installing The Screw For The Front Engine Pad And The Torque Rod Mounting In The Transmission
- Installing And Tightening Front Suspension Components
- Tightening The Ball Joint Pinion
- Installing The Nuts On The Fender Liner
- Checking The Oil Level In The Transmission
- Checking the oil level
- Installing The Screws For The Transmission And Engine
- Installing The Pipe Junction
- Installing The Bracket And Lever For The Transmission
- Installing The Water Hose
- Installing The Upper Torque Rod
- Finishing
- 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
- Transmission (B6284T; 1999-2001)
- Transmission (B6294S; 2000-2001)
- Transmission (B6294S2; B6294T; 2002-2005)
- Transmission (B6304S3; 1999)
- Oil Sump (B5254T2; 2004-2006)
- Oil Sump (B6284T, 4T65EV-Gt; 1999-2001)
- Replacing The Oil Pan
- Oil Sump (B6294S, 4T65EV; B6294S, 4T65EV-Gt; 2000-2001)
- Oil Sump (B6294S2; B6294T; 2002-2006)
- Oil Sump (B6304S3, 4T65EV; 1999)
- Timing Gear (B5254T2; 2004)
- Timing Gear (B5254T2; 2005-2006)
- Timing Gear (B6294T; 2002-2006)