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Power unit, to remove

Power unit, to remove


1. Position the car on a lift and drape the wings with protective covers. Raise the car slightly until the wheels are clear of the floor.


2. Reduce the fuel pressure by removing the fuel pump fuse while the engine is running. Switch off the ignition when the engine has stopped and refit the fuse.

3. Place the wheels in the straight ahead position and unbolt the steering column from the steering gear inside the cabin.

4. Remove the engine cover and battery cover.


5. Disconnect the battery cables and remove the battery.

6. Remove the battery tray and detach the wiring harness fasteners from the battery tray.

7. Unplug the connectors from the automatic transmission's wiring harness.

8. Remove the front wheels and hub nuts. Unscrew the ground cable, which is connected to the gearbox casing, in the left-hand wheel housing.


9. Remove the ground cable from the gearbox.

10. Withdraw the gearbox venting hose.

11. Detach the selector lever cable from the gear actuator and move the cable aside.

12. Disconnect the positive cable from the junction terminal and its fasteners on the main fuse board.


13. Detach the throttle cable from the throttle body and retaining bracket. Bend aside.

14. Remove the turbo pressure hose from the throttle body.


15. Unplug the connectors from the turbo pressure sensor and the intake air temperature sensor and disconnect the ground cable from the turbo pressure hose's connecting pipe.

16. Raise the car additionally. Detach the turbo pressure hose from the charge air cooler. Remove the lower spoiler sections.


17. Remove the air cleaner's rubber mounts from the subframe.

18. Drive two wedges, part No. 83 95 238, between the oil sump and subframe and between the gearbox and subframe.


19. Detach the rear heated oxygen sensor's wiring from its attachments in the floor (certain models).

20. Separate the front exhaust system after the catalytic converter.


21. Detach the anti-roll bar link rods at the link arms.


22. Detach the outer tie-rod ends from the suspension struts.

23. Unscrew the lower steering swivel joint bolts from the link arms.

24. Place a receptacle under the car and open the radiator's drain cock.


25. Lower the car and unscrew the expansion tank filler cap.

26. Detach the vacuum hose from the charge air bypass valve and remove the turbo pressure hose together with the bypass pipe, valve and connecting pipe.

27. Remove the heat shield from the front exhaust manifold.


28. Detach the crankcase breather pipe from the turbo intake pipe. Collect the sealing washers.

29. Unplug the connector and remove the mass air flow sensor and intake hose. Disconnect the venting hose's quick-release coupling and remove the turbo's intake pipe.

30. Unplug the connectors and remove the radiator fan.


31. Remove the wiper arms, using special tool 85 80 144, and the windscreen cover.


32. Remove the engine control module's rubber seal and its connector.

33. Remove the cover over the engine wiring harness connector on the bulkhead. Separate the connector and remove the wiring with holder and place it on the engine.

34. Detach the vacuum hose from the heater system's shut-off valve.


35. Detach the brake servo's vacuum hose from the intake pipe connection by moving the red part of the hose in towards the intake pipe and pulling it outwards.

36. Detach the venting hose from the throttle body.

37. Undo the fuel rail connections. Have an absorbent cloth or paper handy to catch any fuel spillage. Carefully bend the hoses aside.


38. Detach the power steering oil reservoir from its bracket and undo the cable tie securing the hydraulic hoses. Fix the reservoir with hoses to the engine. Make sure that no oil leaks out of the reservoir's ventilation hole.

39. Detach the upper and lower radiator hoses and the hoses connected to the expansion tank and radiator.


40. Detach the automatic transmission's hydraulic hoses. Place a receptacle underneath. Fit a plastic bag or the like over the hose connections. Plug the oil cooler connections.

41. Remove the radiator.


42. Undo the hose connections for the cabin heat exchanger. Note the location of the hoses for subsequent assembly.


43. Remove the hose between the turbo's outlet and the charge air cooler.


44. Remove the front grille.

45. Hang up the charge air cooler and condenser with a cable tie, part No. 83 95 212.

46. Unplug the A/C compressor's connector.


47. Secure and lower a cable tie, part No. 83 95 212, which will later be used to suspend the A/C compressor.

48. Detach the A/C pipes from the attachment points on the subframe.

49. Release the multigroove belt from tension and remove the right-hand engine mount with attachment and bracket.


50. Undo and remove the left-hand engine mount.


51. Check to make sure that everything has been detached and moved aside so that no damage will occur when the engine is removed.

52. Raise the car and place lifting trolley 83 94 793 with lifting table and fixtures under the power unit. The vertical adjustment arrangement on the fixture should be in its lowest position.


53. Raise the lifting table and adjust it according to the locating points on the car body and fixture. Continue raising the lifting table until it touches the subframe. Raise it a little more and then adjust its height until it abuts evenly against the subframe.

54. Undo the subframe retaining bolts and the triangular stiffeners.


55. Carefully lower the power unit slightly, remove the drive shafts from the hubs and make sure that the generator's cooling duct has come away from its connection.

56. Remove the A/C compressor retaining bolts. Lift out the compressor and secure it with the previously mounted cable tie.


57. Lower the power unit additionally. Take care to ensure that nothing catches on it and that nothing has been left in place which could be damaged when the engine is removed.