Removal
NOTE:
- Refer to Special Tools
- The engine/transmission assembly is removed as a unit from below.
1. Raise vehicle at the jacking points, refer to Raising The Vehicle.
2. Disconnect ground cable from battery.
3. To avoid injury, slide a suitable protective cover over the upper lock section protruding from the engine compartment cover, e.g. a piece of hose.
4. Disconnect plugs, remove air conditioning compressor from console and leave it attached to the hoses connected to it. The compressor may be placed on a suitable rigid support on the left-hand side panel.
5. Remove hot air blower.
6. Remove air cleaner assembly.
7. Disconnect crankcase/oil tank vent hoses.
8. Drain reservoir of power steering pump (draw off fluid). Pull spark plug connectors off cyls. No. 4 and 5. Place suitable pan under hydraulic pump. Disconnect hoses and catch remaining oil in a pan. Always plug pump openings and hoses (to prevent dirt ingress).
9. Disconnect plug from intake rail. Take care not to lose the plug seal.
10. Disconnect the following connectors or wires, respectively, in the left-hand front engine compartment area:
11. Undo cover of electrical system of engine compartment. Disconnect connectors carefully (to avoid breakage).
NOTE: Release connector A before pulling it off.
11a. Remove right-hand cover next to air conditioning compressor, unlatch oxygen sensor plug and disconnect plug.
Part 1 Of 2:
Part 2 Of 2:
12. Undo fuel return and fuel supply line, using a second wrench to lock.
13. Unlatch throttle operating cable from pedal return lever, back off lock nut and take off ball joint.
14. Raise vehicle
15. Remove engine/transmission guard and rear underbody paneling.
16. Release ball clamps and remove tailpipes from rear mufflers.
17. Remove both rear mufflers.
NOTE: The rear mufflers engage into their brackets at the top.
18. Undo drive shafts at the transmission flange and place them on the side sections of the subframe. Protect the drive shafts against damage, e.g. with hose sections.
19. Undo hexagon head screw and pull selector rod coupling off the internal shift rod.
20. Remove hot air hoses, hot air pipes, hot air flaps and front transverse strut.
21. Remove complete stabilizer assembly.
22. Mark position of toe eccentrics (A area).
22a. Loosen fastening nut no. 1 (without removing it). Remove toe eccentric (A area). Rotate toe control arm 2 towards the out-side (detaching it from the cross member).
CAUTION: While doing so, the rubber boot of the ball joint must be rotated as well (arrow); otherwise, the boot might get damaged.
22b. Detach toe control arm 2 on the other side as well and rotate it downwards.
22c. Remove rear cross member.
23. Disconnect oil return line from gearbox.
Thermostat Housing Drain Plug:
24. Release right-hand sill cover and engine oil from thermostat housing. When the engine is to be rebuilt, also drain oil from crankcase.
25. Undo oil return line, using a second wrench to lock. Plug oil line (36 AT) and screw-in flange (32 A/F).
26. Release hose clamp and pull hose off the oil pipe. Catch remaining oil in a pan.
27. Undo wire of term. 30 from starter.
28. Undo ground strap between body (RH inner side panel) and starter from body.
29. Pull throttle operating cable out of its guide.
30. Place engine jack complete with engine mounting plate, applying a slight preload.
NOTE:
a. Observe position of mounting plate. Lock lever in horizontal position.
b. The support blocks on the mounting plate face down.
31. Unbolt transmission crossmember (6 bolts). Unbolt engine mount. (Use long reach socket).
32. Carefully lower engine/transmission assembly somewhat. Working from the engine compartment, unbolt the clutch slave cylinder and suspend it to one side complete with the lines remaining connected.
NOTE: Do not actuate the clutch pedal after the slave cylinder has been removed. Attach a note to this effect inside the vehicle.
33. Lower engine/transmission assembly further, move or place right-hand drive shaft over starter. When lowering the assembly, take care not to damage the lower spark plug connector (cyl. no. 3) and the clutch housing vent line.
CAUTION: When the vehicle is placed back on its wheels, the rear crossmember and both steering arms 2 should by all means be refitted to provide sufficient rigidity.