Engine: Service and Repair

Removal and Installation

Instructions for disconnecting and connecting battery, refer to Service Precautions.
Remove battery negative lead from battery and cover.





Moving engine hood into assembly position:

Note: The following work must be carried out with a second person assisting. Work instruction applies to left and right sides.

Hold engine bonnet/hood.
Raise clamps (1) on both sides and slide upwards.
Unhook dampers (2) on left and right from engine hood.





Raise engine bonnet/hood.
Insert M8 screw (1) in engine hood hinges (2) on left and right for fastening.





Release retaining clips (1).

Caution: The air duct can break at the firewall if not carefully removed and installed.

Carefully turn air duct (2) upwards so that it is no longer locked in firewall. Pull air duct (2) forwards and lift out.
Removing and installing left intake filter housing,
Removing and installing right intake filter housing.
Disconnect plug connections on DME control unit. This operation is described in Replacing Control Unit, refer to Powertrain Management.





Disconnect plug connection (1) on temperature sensor for electronic,, box.
Release locks (2).
Remove strip (3) upwards.
Release nut (4) and remove grounding cable strap.
Disconnect remaining plug connections of engine wiring harness in electronics box.





Detach rubber strip (1).
Release fasteners (2).





Remove retaining clips (1).
Remove heater bulkheads (2) and (3).
Lay engine wiring harness on engine.





Disconnect plug connection (1) on oil pressure switch. Release screw (2) and remove grounding cable. Release screws (3) and remove main flow oil filter housing from holder.

Note: Oil lines remain connected.





Release screws (1) on right floor panel (2).
Press right floor panel (2) downwards a little.





Pull off cap (1) on battery positive lead.
Release nut on battery positive lead (2).
Disconnect battery positive lead (2).
Loosen screw (3)
Remove cable holder (4).
Release expansion rivet (5).
Pull panel (6) down a little.
Withdraw battery positive lead (2).





Unfasten cable clip (1).
Remove battery positive lead (3) from lead holders (2).
Remove transmission.
Drain off and top up coolant.
Remove and install radiator, refer to Cooling System.
Remove alternator drive belt, refer to Drive Belts, Mounts, Brackets and Accessories.
Remove A/C compressor drive belt, refer to Drive Belts, Mounts, Brackets and Accessories.
Evacuate air conditioner and remove A/C compressor.
Remove power steering pump and place to one side.

Note: Lines of power steering pump remain connected.

Remove microfilter housing on left.
Remove low pressure lead from brake booster.





Release locks (1).
Remove strip (2) upwards.
Unfasten hose clip (3) and remove hose.

Note: Catch and dispose of fuel as it escapes.

Disconnect quick-release coupling (4) on fuel hose.
Pull off vacuum hose (5).





Unfasten hose clip (1).
Detach coolant hose for heating.





Pull off lock (1).
Detach water hose from return line.


Installation:
Slide lock (1) back.
Water hose must snap audibly into place.
Remove right exhaust manifold, refer to Exhaust System.





Unfasten ground tape from right of engine support.
Unfasten top left and right nuts on engine mount.





Note: A bracket for cable duct is screwed down with nut (1).

Release all nuts. Remove cover from intake air manifold.
Installation:
1. Install all nuts
2. Tighten down nuts (2) to approx. 5 Nm
3. Tighten down remaining nuts to approx. 5 Nm
4. Tighten all nuts to approx. 10 Nm

Caution: Only raise engine on locating lugs provided for this purpose.





Suspend engine from special tool 11 0 260.

Caution: Pay attention to following narrow points when lifting engine out:

1. Lines on A/C compressor
2. Lines on power steering pump
3. Heating valves
4. Exhaust manifold, left
5. Cylinder head covers
Carefully lift out engine.





Installation:
Install engine mount in front bore (1) of support bracket.