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 holding rear tunnel cover and remove cover. Disconnect plug connectors for electronic speedometer in tunnel and pull out rubber sleeve with cable plug.






13. Unscrew hex screw in selector rod coupling and detach from internal selector arm of transmission.






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






16. Remove rear stabilizer.
17. Disconnect ground strap on body.
18. Disconnect 3 cables from starter.






19. Remove retaining clamp and disconnect accelerator pull rod. Unclip clutch cable to release cylinder from its holder.






20. Unbolt clutch release cylinder and move aside with line connected.

Note: Under no circumstances should the clutch be depressed with the release cylinder unbolted.

21. Remove the stud bolts holding the propshaft to the differential flange.









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






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






26. 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 / transmission assembly.
2. Tightening torque.
Hexagon head bolts for engine and transmission carriers = 80 Nm (58 ft lb).
Socket head bolts for propeller shaft flange 42 Nm (30 ft lb).