Removing and installing

The engine/transmission assembly is removed as a unit from below.

Removal

1. Raise vehicle at the jacking points.

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

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.

1594-10

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).

1593-10

9. Disconnect plug from intake rail. Take care

1475- 15

1 - to carbon canister

2 - to brake booster

4 - to knock sensor

5 - cruise control connector

6 - to reference mark sender

11. Undo cover of electrical system of engine compartment. Disconnect connectors carefully (to avoid breakage).

10. Disconnect the following connectors or wires, respectively, in the left-hand front engine compartment area:

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.

1630-15

12. Undo fuel return and fuel supply line, using a second wrench to lock.

1595-10
1596-10

13. Unlatch throttle operating cable from pedal return lever, back off lock nut and take off

14. Raise vehicle

15. Remove engine / transmission guard and

16. Release ball clamps and remove tailpipes

17. Remove both rear mufflers.

Note

The rear mufflers engage into their backets 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 selec tor rod coupling off the internal shift rod.

1616-10

21. Remove complete stabilizer assembly.

22. Mark position of toe eccentrics (A area).

1635-10

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.

1616-10

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).

Important:

While doing so, the rubber boot of the ball joint must be rotated as well (arrow); otherwise, the boot might get damaged.

1635-10

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.

20. Remove hot air hoses, hot air pipes, hot air flaps and front transverse strut.

24. Release right-hand sill cover and engine oil from thermostat housing. When the en gine is to be rebuilt, also drain oil from crankcase.

1454-03

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

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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.

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32. Carefully lower engine/transmission assem bly 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.

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31. Unbolt transmission crossmember

(6 bolts). Unbolt engine mount. (Use long-reach socket).

Installation

Observe the following aspects during

1. Replace all fastening nuts.

2. Install engine/transmission unit.

3. Fit toe control arms 2 to cross member.

Before fitting toe control arms 2 to the cross member, check weight and quality category

Required quality 10.9 (initial version 8.8 /

see parts catalogue). The quality category is indicated on the screw head.

Replace eccentric, if required (e.g. if thread not o.k. or if quality category 8.8).

In this case, transfer the position marks to the

To tighten the eccentric (A area), proceed

4. Tighten the toe eccentric (A area) in zero position. Tightening torque: 100 Nm

Zero position: Toe control arm 2 and rear cross member form a horizontal line. To obtain this zero position, lift wheel carrier

The toe eccentrics can also be tightened after the vehicle has been put on its wheels and has been rocked back and forth approx.

5. Check whether all plugs have been removed completely from the oil hoses and oil pipes and especially from the bends of the hoses and pipes.

6. Tighten the fastening screw of the gearshift rod coupling. Tightening torque 23 Nm

7. Fit accelerator cable from below. Make sure the rubber sleeve fits properly.

2118-10

8. Put the engine compartment rubber seal between body and engine paneling in place correctly before installing the engine/ transmission unit in its final position.

9. Make sure the inner rubber seals of the

10. Fit lid of assembly bores of engine suspension:

Put the metal lid in place from below. The holding brackets on the lids must face upwards into the engine compartment. As shown in the figure, the holding brackets must be positioned at a right angle to the direction of travel in the "a" area. Only in this area is a tight fit ensured.

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