Removal

NOTE: The engine and transmission assembly is removed as a unit from below,

Operations With Vehicle Lowered
1. Raise vehicle slightly at jacking points.
2. Disconnect battery ground cable.
3. Place a suitable protective cover or a piece of hose on upper lock section protruding from engine compartment cover (to avoid injury). Place rear protective cover into position.





4. Disconnect connector, remove air conditioning compressor from console and leave it attached to the hoses connected to it. The compressor can be placed on a suitable rigid support on the left-hand side panel.
5. Remove complete air cleaner assembly.





6. Remove switch-over flap (fresh air / engine air) and rear heater blower.





7. Remove cover of electrical system in engine compartment. Disconnect connectors carefully (to avoid breakage).

NOTE: Unlatch connector A before pulling off.





8. Disconnect the following connectors or wires in left front engine compartment area:





9. Undo hexagon head bolt and take off wiring bracket. Disconnect connectors. (Take care not to damage connector seal).





10. Pull off both hose connections of crankcase/oil reservoir breather.





11. Detach breather hose from resonance flap housing.





12. Release throttle operating cable. Push rubber grommet out of bracket.





13. Pull off cover, unlatch oxygen sensor connector and pull off connector.





14. Drain power steering pump tank (draw off fluid). Pull off spark plug connectors of cyl. No. 4 and cyl. No. 5. Place suitable container under power steering pump. Undo hoses and catch spilling fluid. Plug all openings immediately (to prevent dirt ingress).

Left Side (Fuel Return):

RH Side, Fuel Supply:

15. Undo fuel return and fuel supply lines, using a second wrench to lock. Catch overflowing fuel in a suitable pan.





16. Remove rear oddments tray from center tunnel console. The fastening screw is located under the rubber insert. Flip damping tab over. Remove cover. Unscrew central tube to transmission fastening bolts.

Operations With Vehicle Raised Off The Ground:
1. Take off undertrays of engine, transmission and central tube.
2. Release ball clamps and remove tailpipes from rear mufflers.
3. Take off both rear mufflers.

NOTE: The rear mufflers engage into their brackets at the top.

4. Unbolt drive shafts from transmission flange and place them on the side sections of the subframe. Protect drive shafts against damage, e.g. with short hose sections.
5. Push rubber boot forward over shift rod coupling and release fit bolt.





6. Unscrew both Allen bolts from clamping sleeve and push clamping sleeve forward on central shaft.





7. Install shop-made flat iron bar tool. (To support central tube when unbolting the tube).





Diagram of shop-made tool





8. Take off heater air hoses, heater air pipes, heater air flaps and front transverse strut.
9. Remove complete stabilizer bar assembly.

Toe Arm Removal (Part 1 Of 2):

Toe Arm Removal (Part 2 Of 2):

10. Separate toe arms (arm No. 2) at both ends. Slacken outer mounting (arrow A) only. Mark installation position of inner mount (toe eccentric, arrow B), e.g. with a scriber, and highlight mark with a dot of paint. Remove toe eccentric (arrow B) and separate control arm.





11. Mark position of rear crossmember. Remove crossmember (four mounting bolts).

Thermostat Housing Drain Plug:

12. Undo right-hand sill cover and drain engine oil from thermostat housing. When the engine has to be rebuilt, also drain oil from crankcase.
13. Undo ground strap between body and starter motor from lower starter mount.
14. Release wire No. 30 from starter.
15. Unbolt clutch slave cylinder and suspend to one side complete with the fluid line remaining connected.
16. Separate oil return line from transmission.





17. Undo oil return line, using a second wrench to lock. Plug oil return line (36 A/F) and screw-in flange (32 A/F).





18. Release hose clamp from oil supply line and catch remaining oil in a pan.
19. Place jack with engine support plate under vehicle, placing jack under light preload.








NOTE:
a. Notice position of support plate. Lock lever in horizontal position.
b. The support blocks of the support plate point downward.

20. Undo transmission crossmember (6 bolts). Unbolt engine mount (use long socket).
21. Take off inspection cover of assembly cutouts for engine mount in rear engine end plate and undo hexagon head nuts from engine mounts.
22. Lower engine/transmission assembly until central tube rests on the shop-made flat iron bar.
23. Lower engine/transmission unit further. Move or place right-hand drive shaft over starter. Take care not to damage lower spark plug socket (cyl. No. 3) and clutch housing breather pipe and accelerator cable when lowering the assembly.

CAUTION: When the vehicle is placed on its wheels, the rear cross member and both arms No. 2 should be installed to ensure stability of the vehicle.

NOTE: Do not actuate the clutch pedal when the slave cylinder has been removed. Attach a note to this effect inside the vehicle.