Engine: Service and Repair

REMOVAL

NOTE:
- Engine is removed from below.
- Clutch housing remains on engine.
- Procedure for manual transmission only.

1. Set up lifting platform and lift car on jacking points.
2. Place protective covers on fenders.
3. Loosen and remove front wheels.
4. Disconnect ground lead on battery/body. Disconnect positive battery cable, separate cable harness, and push both cables with the rubber grommet through the fire wall. Open wire straps.

DME and Knock Control Units:

5. Unscrew and remove cover in foot well of passenger side. Unscrew carrier for DME and knock control unit and remove both multiple-pin plugs. Disconnect vacuum hose on knock control unit. Disconnect four-pin plug.

Cruise Control Motor:

6. Loosen fuel return hose clamp and pull off hose. Unscrew fuel feed hose, while counter- holding. Disconnect cable on cruise control motor.
7. Unscrew and remove air cleaner upper section.

Air Pipes:

8. Remove both charging-air guide pipes.

Air Cleaner:

9. Remove air cleaner lower section together with air flow sensor.
10. Unscrew and remove distributor cover. Remove oil filter and ATF supply reservoir.

Throttle Cable:

11. Disconnect throttle operating cable. Disconnect oxygen sensor plug connection arid loosen wire straps. Unscrew coolant expansion tank cap.

Lower Trim and Splashguard:

12. Remove front and lower trim panel and engine splashguard.
13. Unscrew coolant drain plug and catch escaping coolant. Disconnect alternator venting hose.

Oil Cooler:

14. Loosen and remove coolant hose on radiator at bottom right and on engine. Catch escaping coolant. Disconnect oil cooler from body, allowing it to hang on the hoses.
15. Pull off electric wires on fan motors. Unscrew fan motor brackets on radiator and remove r1rom below.
16. Loosen coolant hoses on coolant pipe (cross member) and remove cross member.

Coolant Hose:

17. Unscrew and remove coolant hose and vent hose on radiator at top left. Remove electric connection from temperature switch on radiator.

Expansion Tank:

18. Loose and remove coolant hose from expansion tank to turbocharger. Disconnect tank discharging valve suction hose on intake air cowl. Remove coolant pump with its bracket from body.

Radiator Holder:

19. Detach radiator holder and remove radiator from above. Unscrew radiator mount and remove from body.

Suspending Engine:

20. Suspend engine frow1 front transporting bracket with Special Tool 10-222 A, and hold in installed position.

A/C Compressor:

21. Loosen poly-rib drive belt tensioner on a/c compressor and remove belt. Unscrew compressor on console and allow it to hang down to the side (refrigerant hoses remain connected).
22. Unscrew and remove stabilizer with holders on body and control arms. Disconnect left and right tie rods.

ATF Cooler:

23. Loosen hose clamps between steering cooler and steering, and disconnect hose.
24. Unscrew power pump from console and let it hang down on steering.

Control Arm:

25. Unscrew left and right control arms on front axle cross member and rear mount, and pull out from front. (Console bolts must not be loosened).

Steering Linkage:

26. Unscrew universal joint from steering gear and upper hydraulic engine mounts from engine supports. Remove front axle cross member with steering c~ear and power pump from below.

Deflection Plate:

27. Unscrew deflection plate on starter and clutch housing and remove toward rear.
28. Disconnect electrical connections on starter and unscrew starter. Loosen hose clamps on clutch housing.
29. Unscrew clutch slave cylinder on clutch housing (line remains connected).

Exhaust Assembly:

30. remove exhaust assembly together with catalytic converter. Unscrew bolts on flange between turbocharger and exhaust pipe, as well as flange on bypass valve.

31. Unscrew flange after catalytic and suspension, and remove assembly.
32. Unscrew hose clamp, exhaust flange, and bypass valve holder. Remove bypass valve. Unscrew bracket on transaxle at bottom and push back.
33. Unscrew upper transaxle I clutch housing mounting bolts.
34. Disconnect coolant hoses for heater above exhaust manifold and on cylinder head.

Firewall Connections:

35. Loosen wire strap on firewall. Disconnect two-pin and multiple- pin plugs. Pull off vacuum hose on tank discharging valve and brake booster. Remove diagnosis plug from holder downward.

Suspending Unit:

36. Connect Special Tool 3033 in transporting bracket of engine as described below:
- Pulley: Position. 3
- Flywheel: Position. 11
In Position 3 the threaded rod is "below" the suspension unit. In Position 11 the threaded rod is "above" the suspension fixture.
37. Slightly tighten suspension fixture on engine using a shop hoist, e.g. K 750 H, and remove Special Too 10 - 222A.
38. Remove lower transaxle/clutch housing mounting bolts.
39. Pull engine forward, press rubber sleeve out of separating wall towards engine compartment, and remove wire harness carefully.
40. Separate engine from central tube or central shaft, and lower engine.

INSTALLATION
The following should be observed:
1. Carefully guide wire harness for DME and knock control unit, multiple-pin plug, and vacuum hose into footwell on passenger side.
2. Screw in transaxle/clutch housing mounting bolts first, but do not tighten.

NOTE: Tighten mounting bolts to final torque only after installation of hydraulic engine mounts on front axle cross member. Tightening torque of mounting bolts: 42 Nm (30 ft lb).

Control Arm:

3. Install control arms. For easier installation, press down slightly on sleeves in rubber/middle mounts.
4. Make sure radiator fits properly in rubber mounts.
5. Tighten bolts and nuts to specified tightening torque.

Coolant Bleed:

6. Fill and bleed cooling system.
7. Fill supply reservoir with ATF and bleed steering system.
8. Run engine to operating temperature. Check engine oil and coolant level, correcting if necessary.