To Remove and Fit

The removing and fitting procedure described here is for a car with the B201 Turbo engine with intercooler, catalytic converter and water-cooled turbocharger.
For other models and engine versions, follow relevant parts of the description to suit each individual case.

TO REMOVE





1. Remove the bonnet by releasing the links at each hinge, and disconnect the hose for the washers. Place the bonnet securely, such as by leaning it against a wall, to prevent it from being damaged.





2. Fit tool 83 93 209 between the right-hand upper wishbone and the body. Turn the steering wheel to the right-hand lock and fit the tool from the wheel housing side.





3. Disconnect the cables from the battery. Remove the battery (Turbo).
4. Remove the exhaust pipe flange bolts.
5. Back off the right-hand front wheel nuts.
6. Drain the oil from the steering servo pump reservoir.
7. Lift the car.
8. From the underside of the car:





a) Remove the nut and carefully tap out the taper pin from the selector rod. Separate the selector rod joint.





b) Disconnect the speedometer cable.





c) Remove the bolts for the exhaust pipe support bracket.





d) Release the clips on the inner universal joints and remove the gaiters from the universal joint drivers.
9. Lower the car to a suitable working height.
10. Remove the right-hand front wheel.





11. Release the end piece from the lower wishbone.

NOTE: Observe cleanliness when carrying out work on the universal joints. Even very small quantities of sander dirt will shorten appreciably the useful life of the universal joints.





12. Separate the universal joint on the right-hand side and move the tripod forward of the universal joint driver. Support the end piece against the outer end of the wishbone. Cover the universal joint driver and the tripod to exclude dirt.





13. Release the pipe coupling on the delivery side of the steering servo pump. Plug the pipe and avoid spilling oil on the engine mounting.
14. Cars with AC: Screw out the tensioner and remove the drive belt for the AC compressor.
15. Remove the drain plugs from the underside of the engine block and radiator, and drain the engine coolant.
16. Disconnect the coolant hoses at:





a) Heat exchanger valve

NOTE: Mark the hoses to make sure that they will be reconnected to the right places. The upper hose comes from the coolant pump.

b) Expansion tank
c) Thermostat housing





17. Disconnect the solenoid valve signal hoses from the valve.





18. Remove the turbocharger delivery pipe between the intercooler and the throttle housing.
19. Remove the rubber bellows at the fuel distributor.





20. Remove the cover over the intercooler. Remove the intercooler, together with the air pipe.





Fit a blanking-off cover to the turbocharger suction pipe.

21. Remove the fuel distributor and the air cleaner as follows:





a) Remove the air cleaner "snorkel".





b) Disconnect the vacuum hose from the pressure switch, remove the retaining screw and move the switch to one side.





c) Disconnect the fuel hoses from the control pressure regulator. Use two spanners. Carburettor engine: Disconnect the fuel hoses from the fuel pump and disconnect the return line.





d) Disconnect the fuel hose from the cold-starting valve.

NOTE: Carefully check the run of hoses to the fuel distributor and note the various connections. Mark the hoses, if necessary.





e) Disconnect from the fuel distributor:
- the hose from the fuel filter (1)
- the hose from the fuel-boosting valve (2)
- the return fuel hose (3)
- the hose for the control pressure regulator and fuel-boosting valve (4)





f) Disconnect the fuel pipes from the fuel injection valves. Use two spanners.





g) Disconnect the earth cable at the fuel distributor. Release the clips and lift off the fuel distributor with air cleaner and fuel hoses.





22. Disconnect the throttle cable and electric cable.
23. Disconnect the vacuum hoses for the brake servo from the intake manifold and the tank vent system from the throttle housing.





24. Release the oil dipstick pipe.





REMOVING THE CABLE HARNESS FROM THE B201 ENGINE





25. Cut off the straps and release the cable harness on the left-hand side of the engine. Then disconnect the wiring at the following points:
a) full-load enrichment switch





NOTE: Note the locations of the cables and mark them if in doubt.

b) cold-starting valve
c) temperature switch, Lambda
d) temperature time switch
e) temperature sensor
f) Hall sensor
g) auxiliary air valve
h) temperature switch
i) earthing points at the lifting lug

NOTE: Note the locations of the cables.

j) control pressure regulator
k) knock sensor
l) starter motor (at the same time, disconnect the positive cable)
m) oil pressure sensor
n) alternator
Place the cable harness on the radiator crossmember.
26. Disconnect the turbocharger coolant pipes from the mounting on the timing gear cover and remove the earth cable.





27. Disconnect the hydraulic hose from the slave cylinder. Use tool 83 935 Plug the hose.





28. Disconnect the coolant hose from the bottom of the radiator.

NOTE: On a car with AC, remove the extra radiator fan.

29. Release the positive cable from its clips on the engine and place it on the battery bracket.
30. Release the ignition coil and disconnect the lead from the distributor cap. Place the coil on the radiator cross-member.





31. Separate the Lamda sensor cable at the connector above the right-hand wheel housing. Release the clip at the wheel housing and lay the cable on the engine.
32. On a car with AC: Remove the four AC compressor bolts and place the compressor on the heat exchanger.
33. Remove all engine mounting bolts. In the left-hand engine mounting, the through bolt is fitted with a spacer sleeve. On cars to US specification, also remove the movement limiters from the front and righthand engine mountings.





FRONT ENGINE MOUNTING





LEFT-HAND ENGINE MOUNTING





RIGHT-HAND ENGINE MOUNTING

NOTE: Cars with air conditioner have a notch in the AC bracket for a lifting hook. If the bracket has been removed, fit a separate lifting lug 93 13 222 instead to the water pump cover. Use the existing bolts.





34. Secure the lifting yoke to the power unit and lift the power unit so that the left-hand inner universal joint can be separated.
35. Disconnect the steering servo pump return line.





36. Remove the oil pressure sensor and disconnect the hoses for the air-cooled oil cooler from the oil filter housing.





37. Lift the power unit out of the car. Take great care to avoid damage, above all to the radiator and solenoid valve. Fit protective caps to the universal joint drivers.

TO FIT THE POWER UNIT
1. Check that the universal joints are packed with grease. Refit the drain plugs for the cooling system.





2. Suspend the power unit from the lifting yoke so that the front engine mounting is somewhat lower than the rear mountings.





3. Lower the power unit into the engine compartment down to a height at which the oil cooler hoses, the oil pressure sensor and the steering servo pump return hose can be connected.
4. Align the power unit in the following order:
- front engine mounting
- left-hand inner universal joint
- right-hand inner universal joint

Then lower the power unit onto the rear engine mountings and fit the bolts. Don't forget the spacer sleeve for the left-hand mounting.
5. Unhook the lifting yoke hooks and, if applicable, remove the lifting lug from the water pump (car with AC).
6. If the car is equipped with an AC:
- Fit the AC compressor.
- Fit the drive belt and tension it.





7. Connect the pipe coupling on the delivery side of the steering servo pump.
8. Secure the exhaust pipe loosely to the exhaust manifold.





9. Lift the car to a suitable height and fit the ball joint to the bottom wishbone and antiroll bar.
Refit the wheel.
10. Lift the car and fit the following:





a) The rubber gaiters and clips to the universal joints.





b) The bolts for the exhaust pipe bracket to the gearcase. The exhaust pipe clamp may have to be slackened slightly to enable the bracket to be bolted to the gearcase.





c) Speedometer cable.





d) Selector rod taper pin.
11. Lower the car to a suitable working height and:
- Connect the earth cable to the timing gear cover.
- If the car has a water-cooled turbocharger, connect the coolant pipe to the turbocharger.
- Run the positive cable into place and fit the clips.





12. Remove tool 83 93 209 under the right-hand upper wishbone and tighten the wheel nuts.
Tightening torque for the wheel nuts up to and Inci. the 1987 model: 90-110 Nm (66-81 lb ft)
Tightening torque for the wheel bolts as from the 1988 model: 105-125Nm (77-92 lb ft)
13. Tighten the exhaust pipe flange bolts





14. Connect the Lambda sensor connector. Fit the clip to the wheel housing and secure the cable.





15. Connect the radiator hose to the bottom of the radiator and connect the hydraulic line to the clutch slave cylinder.

Bleed the clutch.
Refer to "To Bleed the Master and Slave Cylinder" at Clutch, M/T, Service and Repair. Service and Repair





16. Run the cable harness into place and make the connections to the following terminals in the order listed:
a) full-load enrichment switch

NOTE: Make sure that the cables are connected to the correct terminals on the full-load enrichment switch and to the earthing points on the lifting lug.





b) cold-starting valve





CONNECTING THE CABLE HARNESS TO THE B201 ENGINE

c) temperature switch, Lambda
d) temperature time switch
e) temperature sensor
f) Hall sensor
g) auxiliary air valve
h) temperature switch
i) earthing points on the lifting lug





Note the locations of the cables.

j) control pressure regulator
k) knock sensor
l) starter motor: At the same time, connect the positive cable.
m) oil pressure sensor
n) alternator
Secure the cable harness with straps to the positive cable and to the mounting points on the flywheel housing.








17. Connect the vacuum hoses for the brake servo to the intake manifold and the tank vent system to the throttle housing.
18. Connect the throttle cable and the electric cable.
19. Place the fuel distributor with air cleaner in position and secure them.
Make the connections to the fuel distributor in the order listed below:





a) Connect the earth cable to the fuel distributor.





b) Connect the following to the fuel distributor:
- hose from the fuel filter (1)
- hose from the fuel-boosting valve (2)
- fuel return hose (3)
- hose for the control pressure regulator and the fuel-boosting valve (4)





c) Connect the fuel lines to the control pressure regulator.





d) Connect the fuel hose to the cold-starting valve.





e) Connect the fuel lines to all injection valves.





f) Fit the pressure switch and connect the vacuum hose.





g) Fit the air cleaner "snorkel".
20. Fit the oil dipstick pipe.





21. Remove the protective cap from the turbocharger suction pipe and fit the inter-cooler together with the air pipe.
Fit the cover over the intercooler.
22. Fit the rubber bellows to the fuel distributor.
23. Fit the turbocharger delivery pipe between the intercooler and the throttle housing.
24. Connect the coolant hoses to:





a) heat exchanger valve





b) expansion tank





c) thermostat housing





25. Connect the signal hoses to the solenoid valve.
26. Fit the ignition coil and connect the lead to the distributor cap.
27. Fill the steering servo reservoir with Texaco Power Steering Fluid 4634 or equivalent.
28. Fill the cooling system with coolant and pressure test it.
29. Fit the battery and connect the cables.
30. Fit the bonnet and connect the hose for the windscreen washers.
31. Start the engine, check the various functions and check that none of the hoses are leaking.