Removal and Replacement

Removal

Raise the car at the jacking point.
Disconnect ground cable from the battery.






Disassemble the air-conditioning compressor from the console and, with lines still connected, lay it on the adequately protected left-hand rear fender.

NOTE: If the hoses are disconnected from the compressor, the air-conditioning system must be bled again.

Remove charge air cooler and air filter system.

NOTE: Cover the opening into the turbocharger.






Disconnect the crankcase vent hose and the hose from the oil separator.
Remove the cover from the engine electric system, separate the multiple plugs for engine cable harness and switchgear, as well as the round connector.






Disconnect fuel hoses:
A. from the fuel filter
B. from the pressure accumulator
C. in the return line, then pull out of the rubber bushing (Fixed to the air pump).






Disconnect the brake booster hose.
Undo the Phillips screws in the tunnel cover and remove the cover. Separate the tachogenerator plug connections in the tunnel and pull the rubber bushing with cable connector outwards.






Raise the car, undo the hexagon head screw in the shift rod coupling and pull away from the inner shift rod in the gearbox.






Drain engine oil and disconnect the oil hoses from the engine and oil tank.
Disconnect the earth strap from the chassis.
Undo the heating hoses at the heat exchangers and pull off.






Remove rear anti-roll bar.
Undo the connecting lines at the starter.






Remove the safety strap and disengage the accelerator tie rod. Unclip the line for the clutch operating cylinder.






Disconnect the clutch operating cylinder and hang up with line connected.

NOTE: The clutch must never be operated if the cylinder has been disconnected.

Undo the FILLISTER head screws connecting the halfshaft flange to the differential.









Position trolley jack with engine mounting plate at the gravity center of the engine/gearbox assembly and raise jack until slightly pretensioned.

NOTE: Make sure that the mounting plate is in the correct position. Lock the lever in horizontal position.

Remove hexagon head bolts from gearbox mount.
Remove hexagon head bolts from engine carrier.
Lower jack with engine/gearbox assembly carefully and move away to the rear.

CAUTION: If the car is moved without the engine/gearbox assembly, the halfshafts must be secured in a horizontal position (to avoid damaging the rubber boots).

Installation

Install in the reverse order of removal.






Make sure that the brake line is routed correctly.

CAUTION: Do not trap the heating hoses, slide onto the heat exchanger just before the engine/gearbox assembly is in the correct installation position.

Tightening torques:
Hexagon head bolts for engine and gearbox carriers 80 Nm (59 ft lb)
Apply a film of Optimoly HT to the bolts (up to the hexagon head) FILLISTER head bolts for halfshaft flange M 10 83 Nm (61 ft lb).

Rectify pressure marks in the engine carrier plate on the crankcase.