Manual Transmission Models

Manual Transmission Models
Special Tools Required:
^ 11 0 001
^ 11 0 002
^ 11 0 003
^ 11 0 009
^ 11 8 351
^ 11 8 352
^ 11 8 401
^ 11 8 402
^ 13 5 280
^ 51 2 160

Turn off ignition.

Disconnect battery.

Remove battery box.

Remove exhaust manifold.





Remove starter motor heat shield retaining bolt (1).

Remove oxygen sensor from wire clip (2).

Remove heat shield.
Tightening torque: 9 Nm.





Remove starter motor connections (1) and (2).
Tightening torque: 14 Nm.
Tightening torque: 8 Nm.

Note harness routing.

Remove alternator drive belt.

Remove cover from injector rail.

Remove tank venting valve lower pipe from stabilizer bracket.

Remove earth lead from engine mounting bracket.





Release fuel pressure from fuel line.

Remove pipe from injector rail and block ends using special tool 13 5 280.

Remove brake booster pipe connection from manifold and unclip from bracket.

Push circular ring down to release pipe (1).





Remove block connector from fusebox (1).

Remove retaining bolts (2) from fusebox and move to one side.
Tightening torque: 5 Nm.





Remove earth lead from left strut (1).
Tightening torque: 9 Nm.

Disconnect round connector (2).





Drain coolant.

Remove clutch slave cylinder retaining bolts (1) and remove clutch slave cylinder (2).
Tightening torque: 24 Nm.

Disconnect both heater pipe connections and expansion pipe connection to fill tower.





Remove clips from gearshift cable housing location (1) and remove gearshift cables (2) from ball joint.

Remove gearshift cable abutment bracket bolts (3) and remove gearshift housing (4).
Tightening torque: 22 Nm.

Disconnect top hose from radiator.

Remove top stabilizer bracket.
Upper stabilizer bracket to body mounting 100 Nm
Upper stabilizer bracket to engine mounting 100 Nm





Drain gearbox.

Remove lower stabilizer bracket bolts (1) and remove bracket (2)
Lower stabilizer to oil sump holder 100 Nm.

Remove driveshafts.





Disconnect steering pump motor connectors (1).





Remove crush tubes.

Slacken modular front end and fit special tool 11 8 401 and 11 8 402.





Disconnect connector from a/C compressor (1).

Remove a/C compressor retaining bolts (2) and lower compressor (3). Secure compressor to modular front end. Unclip air conditioning high pressure pipe.
Tightening torque: 25 Nm.

Remove coolant hose from water pump.





apply suitable tape (1) to both chassis members to protect paintwork when removing engine.





Remove bonnet top strut and insert special tool 51 2 160





Remove engine breather valve from inspection cover and remove valve retaining bolt.

Fix engine lifting equipment to engine and gearbox brackets, special tool 11 8 351 and special tool 11 8 352.
Mount bracket to gearbox 38 Nm
Engine carrier to cylinder block 100 Nm.





Fix engine lifting tool, special tools 11 0 001, 11 0 002 11 0 003 and 11 0 009.

attach engine lifting bracket and chains to engine and support power unit with hoist.





Remove engine mount retaining nut (1).
Tighten Mount 68 Nm.





Remove gearbox to upper mount retaining bolt.
Engine mounting to engine mount 68 Nm.

Remove gearbox upper mount retaining bolts (1) and remove mount (2).
Gearbox upper mount retaining bolts 66 Nm.

Remove engine.