Removal and Replacement

Removing and Installing Engine
Following instructions for disconnecting and connecting battery, see general instructions, refer to Powertrain Management.
Disconnect negative battery lead.





Move engine hood to assembly position:

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

Gently raise retaining clip and simultaneously push upwards.





Hold engine hood, unhook damper on hood.
Slide special tool 51 2 160 over damper.
Open engine hood completely and reconnect damper with special tool 51 2 160 to hood.





Remove microfilter.
Open cable duct on lower section of microfilter housing (2) and feed out cable(s).
Release screws (1) and remove lower section of microfilter housing (2).





Remove engine vent (1).
Remove oil filler cap (2).
Remove engine cover.

Remove engine splash guard.
Remove reinforcement plate refer to Steering and Suspension.

Caution: The section Removing and installing reinforcement plate contains important installation instructions.

Remove A/C compressor drive belt refer to Drive Belts, Mounts, Brackets and Accessories, Drive Belts.
Remove A/C compressor from bearing block and tie back to one side.

Note: Lines remain connected.

Drain and dispose of coolant.

Note: The water drain plug is located on the exhaust side on cylinder 2 in the engine block.

Installation:
Replacing sealing ring on water drain plug.
Tightening torque, refer to Engine, Specifications, Mechanical.

Remove intake air manifold.
Remove throttles.





Pull lock and detach water hoses (1 and 2).

Installation:
Refer to cooling system for general work instructions.

Drain power steering supply tank, detach from left carrier bracket and tie to one side.

Note: Lines remain connected.

Remove Fan Clutch with fan impeller from water pump, refer to Cooling System.
Remove engine oil cooler.
Remove radiator, refer to Cooling System.
Remove alternator drive belt, refer to Drive Belts, Mounts, Brackets and Accessories, Drive Belts.
Remove vane pump for power steering and tie back to one side.

Note: Lines remain connected.

Note: Wiring harness section for engine is disconnected from car and removed with engine.

Disconnect plug connections on DME control unit.

Disconnect wiring harness section from car and lay to engine.

Note: When the engine is being lifted out, there is the danger that the belt pulley may be damaged.

Unfasten screws. Remove belt pulley.





Remove transmission, refer to Transmission and Drivetrain.
Remove starter motor.
Detach steering spindle from steering gear, refer to Steering and Suspension.

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





Fit engine to special tool 11 0 000.

Unfasten right ground wire.
Unscrew left and right engine mounts.
Carefully lift out engine.