Removal and Replacement

REMOVING AND INSTALLING ENGINE

The complete engine/transmission assembly is removed from below.

Removing

1. Take up car on take-up points.
2. Disconnect battery ground wire.



3. If car has an air conditioner, detach compressor on console and leave compressor in car with hoses connected.

Note: Air conditioner must be discharged and charged, if hoses are disconnected on compressor.

4. Take off air cleaner cover with air filter cartridge.



5. Disconnect bottom hose for crankcase breather and top hose from intake hose/ throttle housing on oil tank as well as hoses on air valve.
Also disconnect hose from active carbon cannister on air cleaner of USA cars.



6. Remove hose between extra fan and heat exchangers.



7. Take cover off of central electric board. Pull off multiple pin plug on control board and high voltage lead on ignition coil.
8. Disconnect central engine ground on intake pipe of cylinder no.1.



9. Plug 1 = wire to temperature sensor II cylinder no.3
Plug 2 = wire to speed transmitter (DG)
Plug 3 = wire to reference mark transmitter (BG)
Pull off plugs after pressing in clamp. On USA cars also disconnect plug for oxygen sensor and plug for oxygen sensor heating.






10. Unscrew fuel hoses on filter and return line, being sure to counterhold appropriately.



11. Disconnect hose for brake booster.



12. Unscrew phillips screws on cover for rear end of tunnel and take off cover.
a) Pull seal off of retaining edge on body and push forward over selector rod.
b) Unscrew tapered screw of selector rod coupling and pull coupling off of internal selector arm of transmission.
c) Pull off wires for speed transmitter of electronic speedometer in tunnel and take out rubber sleeve with wire plug.



13. Lift car. Drain engine oil. Disconnect oil hose or oil line on engine and oil tank, making sure to counterhold on the oil line.
14. Unscrew and pull off heater hoses on heat exchangers.



15. Remove rear stabilizer.
16. Disconnect ground strap on body.
17. Disconnect battery wire on starter.



18. Disconnect accelerator pull rod on operating arm and unscrew clutch cable retainer.



19. Remove clutch release lever with spring.
a) Disconnect clutch cable on release lever after loosening cable on holder.
b) Disconnect spring for positioning lever on transmission. Take off cirdip and remove positioning lever.



20. Push release lever forward with a suitable tool.

Note: The spring will expand after passing a pressure point so that the release lever will snap forward.

21. Take release lever off of release lever shaft.



22. Unscrew propeller shaft bolts on flange for differential.

Note: Suspend left propeller shaft from car with a piece of wire to avoid damage on transmission cooling pipe coil when removing and installing engine I transmission assembly.

23. Unscrew rear cowl panel screws and take otf cowl panel with seal.






24. Place workshop jack fitted with engine take-up plate underneath engine / transmission assembly at center of gravity point with slight pre-load.
25. Unscrew bolts on transmission carrier.
26. Unscrew bolts on engine carrier.



27. Lower workshop jack with engine I transmission assembly slightly and pull off multiple pin plug on shock absorber cross member as well as plug on air flow sensor.



28. Lower workshop jack with engine/ transmission assembly carefully and roll Out toward rear of car.

CAUTION: If the car has to be moved after removal of engine / transmission assembly, suspend propeller shafts from car with pieces of wire in horizontal position (prevents damage on dust covers).



Installing

Check following points when installing.

1. Caution ! Do not clamp heater hoses. Connect hoses on heat exchangers shortly before reaching correct installed position of engine I transmission assembly.
2. Tightening torque.
- Hexagon head bolts for engine and transmission carriers = 80 Nm (58 ftlb).
- Socket head bolts for propeller shaft flange 42 Nm (30 ftlb).
3. Mount clutch release lever, coating following sliding and bearing surfaces with a waterproof lubricant, for example, Staburags NBU 12 KB 300 from Klueber, or with a multi-purpose grease.
- release lever bore
- release lever shaft
(also teeth for positioning lever)
- spring bearing surface on console bolts
- clutch cable installation point on release lever.



4. Place seal and release lever on release lever shaft.
Place spring on console bolt.
Push back release lever until spring exceeds pressure point (lever snaps against console stop).
5. Mount position lever (with seal) in correct position. Keep distance between adjusting screw and positioning lever as small as possible after connection of spring.
6. Make basic clutch adjustment.