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Removing the power unit

Removing the power unit

To remove


1. Position the car on a lift and put protection on the wings.

2. Raise the car somewhat so that the wheels are free from the floor.

Warning

In order to avoid the contact roller for the airbag twisting and breaking the steering wheel must be secured via the steering column lock or by taping it to the panel.


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


4. Remove the upper intake manifold between the mass air flow sensor and the turbo.


5. Remove the upper engine cover and the battery cover.

6. Disconnect the battery cables and remove the battery.

7. Undo the maxifuse holder and remove the battery shelf.

8. Detach and move aside the electrical distribution box.

9. Prevent brake fluid from running out of the reservoir by using 30 07 739 Hose pinch-off pliers to block off the brake fluid hose to the slave cylinder.

10. Remove the clip at the slave cylinder and detach the connection to the delivery pipe. Refit the clip.


11. Open the cap on the expansion tank.

12. Remove the front wheels and hub centre nuts.

Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Important

Be particulary observant regardning cleanliness when working on the fuel system. Loss of function may occur due to very small particles. Prevent dirt and grime from entering the fuel system by cleaning the connections and plugging pipes and lines during disassembly. Use 82 92 948 Plugs, A/C system assembly. Keep components free from contaminants during storage.


13. Undo the quick-release couplings on the fuel lines. Use a cloth to catch any fuel spill.


14. Raise the car and remove the lower engine covers.


15. Place a suitable receptacle under the car and drain the cooling system.

16. When replacing the engine (longblock) : Drain the engine oil and replace the oil filter.

17. When replacing the gearbox : Drain the gearbox oil.

18. Remove the side cover from the right and left-hand wheel housings.

19. Carefully and slowly release the tension of the belt tensioner. Remove the multigroove V-belt.


20. Close the coolant drain cock.

21. Fit the oil plug when draining the engine and gearbox oil.

22. Detach both ground cables and unplug the connector of the reversing light switch from the gearbox.


23. Remove the front exhaust pipe.


24. Unplug the connector to the headlamp control module on the link arm (xenon headlamps only).


25. Unplug the connectors to the crankshaft sensor and the oil level sensor.


26. Lower the car, engage 4th gear and remove the plastic plug from the gearbox. Lock 4th gear in the gearbox by inserting 87 92 335 Lock pin.


27. From above, undo the clamp holding the selector rod in the linkage on the gearbox.

28. Lift up the gear lever gaiter. Engage 3rd gear so that the selector rod leaves the linkage and insert 87 92 335 Lock pin into the gear lever housing.

29. Remove the charge air pipe from the turbocharger.


30. Remove the turbo unit cooler hose.


31. Detach the vacuum hoses from the vacuum pump and the hose of the turbo's vacuum box.


32. Detach the hoses to the heater assembly.

33. Remove the nuts on the holders of the starter motor wiring harness.

34. Detach the charge air hose from the upper charge air pipe and plug the pipe.


35. Remove the cable tie and remove the upper radiator hose and the breather hose from the engine and the radiator.

36. Unplug the fan connectors and carefully remove the fan cowling.


37. Detach the lower radiator hose from the thermostat housing.


38. Suspend the radiator in the body using a 83 95 212 Strap . Do not suspend the steering servo cooler that comes down with the subframe.

39. Move the 83 95 212 Strap down towards the AC compressor.

40. Unplug the engine wiring harness connector with the cable ducts.


41. Fit pinch-off pliers to the hoses of the power steering fluid reservoir and remove the reservoir mounting.


42. Detach the banjo pipe from the power steering pump.


43. Undo the bolts of the power steering pump and move the pump aside.

44. Remove the dipstick pipe bolt from the front lifting eye.

45. Unplug the connectors of the oil pressure sensor and the A/C compressor.


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


47. Undo the upper of the A/C compressor screws.

48. Relieve the weight on the right-hand side of the engine carefully using a jack.

49. Remove the right-hand engine mounting, position wedges between the subframe and the A/C compressor bracket as well as between the subframe and the oil pan. Lower the right-hand side of the engine so that it rests against the subframe. Make sure that no pipes or lines are trapped.


50. Relieve the weight of the gearbox carefully using a jack.

51. Remove the nut and the four bolts to the gearbox bracket, position wedges between the gearbox and the subframe. Lower the gearbox to the subframe and remove the gearbox bracket.


52. Set the power steering pump and reservoir on the engine so that they can follow when the power unit is lowered.

53. Raise the car and remove the charge air pipe brackets from the subframe.


54. Remove the AC compressor's screws and lift it from the bracket.


55. Remove the lead-through bolt and detach the lower spindle joint from the steering swivel member on the right and left-hand sides.


56. Remove the nuts securing the track rods and press these out using 87 92 343 Puller.

57. Unscrew the anti-roll bars' upper nuts.

58. Remove the nut to the battery box coolant pipe bracket.


59. Remove the triangular stiffeners.

60. Remove the cables to the starter motor and the generator as well as the cable clip.


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

62. Position 83 95 311 Trolley lift , with 83 94 801 Parent fixture , 83 95 170 Adapter , 83 95 188 Basic fixture and 83 95 196 Holder, front under the power unit. The height adjusters of the fixture must be in their lowest position.

63. 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.

64. Undo the subframe retaining bolts and the two nuts at the air cleaner.


65. Carefully lower the power unit slightly and detach the drive shafts from the hubs using 89 96 951 Puller, drive shaft .

66. Lower slightly further and make sure that the A/C compressor comes out between the subframe and the body so that the engine can move down unhindered. Suspend the A/C compressor using a 83 95 212 Strap.

67. Cut off the cable clips to the battery cable and detach it from the cable duct under the rear exhaust manifold.

68. Lower the power unit more. Be careful to ensure that nothing gets jammed or overlooked during removal and gets damaged.