Removal

CAUTION: The following must be observed during testing or fault-diagnosis work on the engine. To avoid damage that can be caused by arcing at the coil, HT leads, distributor or ECU:





^ never disconnect HT leads when the engine is running
^ never attempt to start the engine with an HT lead disconnected or the distributor cap removed





^ always unplug the ECU before carrying out compression tests or the like

WARNING: Numerous electrical leads, hoses, etc. are secured by plastic cable ties. After these ties have been pulled tight, the excess length is usually cut off, often leaving a sharp edge to the plastic. Bear this in mind when securing ties to avoid leaving sharp edges that could do damage by chafing.

The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner. The procedure will obviously need to be adapted as appropriate to suit cars to different specifications.





1. Raise the car on a lift and remove the middle infill panel from under the spoiler.





2. Remove the drain plug from the radiator and drain off the coolant. Lower the car.





3. Disconnect the battery leads and remove the battery.





4. Remove the fuel-filter strap and move the filter to one side.





5. Remove battery shelf:
- Unbolt the steady bar for the ABS unit, disconnect all electrical connectors and remove all cable ties/clips from the battery shelf.
- Unplug the five-pin connector for the ABS unit.
- Disconnect the positive (+) battery lead from the terminal block on the battery shelf and the earth lead from the terminal block on the wing.
- Tuck the leads out of the way and remove the battery shelf.





6. Unplug the electrical leads from the washer-fluid level sensor and pump. Disconnect the hose from the outlet and, if necessary, plug the outlet to prevent spillage. Remove the two fixing screws and lift out the reservoir.





7. Unplug the connector from the air mass meter. Release the toggle fasteners on the air cleaner body, remove the hose clip on the turbo inlet hose and lift out the air mass meter complete with air-cleaner top.





8. Unplug the connector from the solenoid valve, remove the two fixing screws and lift the valve towards the block.





9. Disconnect the HT lead from the coil at the distributor and unplug the Hall-sensor connector from the distributor.





10. Remove the hose clip and disconnect the top radiator hose.





11. Remove the hose clips on the turbo delivery pipe, disconnect the bypass valve and pressure hose to the transmission, and remove the turbo pipe.





12. Disconnect the throttle cable from the linkage.





13. Disconnect the fuel return hose from the fuel-pressure regulator and tuck the end of the hose up against the false bulkhead panel.





14. Disconnect the fuel supply hose from the fuel-injection rail and place the hose and fuel filter on top of the cover over the space behind the false bulkhead panel, roughly midway along it.





15. Remove the LH cover over the space behind the false bulkhead panel.





16. Remove the rubber moulding from the edge of the false bulkhead panel. Remove the fixing screws and lift out the panel.





17. Remove the strap and remove the ABS-system ECU.





18. Remove the bracket for the ABS-system ECU.





19. Unplug the connector from the LH-system ECU and place the ECU on the wing.





20. Remove the fixing screws and move aside the bracket for the LH-system ECU. Unplug all the connectors on the leads in the main wiring loom for the engine.








21. Remove the TSI socket. Using a small screwdriver, press back the catch on the pin for the violet/white lead (pin 2) and on the pin for the grey/red lead (pin 1) and withdraw the pins.








22. Snip through the tie on the knock-detector lead, unplug the connector and rest the lead on the wing. Rest the main wiring loom on top of the engine.





23. Disconnect at the branch piece the vacuum hose between the pressure sensor and the inlet manifold.





24. Disconnect the heater-box hoses at the engine, snip through the tie for the air mass meter lead and tuck the hoses out of the way.








25. Unplug the road-speed sensor connector, withdraw the lead through the hole in the bottom of the bulkhead panel and rest the lead on top of the engine.








26. Unscrew the clip securing the kickdown cable to the gear-selector cable and the pipe from the steering servo pump.





27. Clean the surrounding areas and disconnect the hoses from the oil-cooler for the automatic transmission. Blank off the ports in the transmission case and the fittings on the ends of the hoses.








28. Remove the nut from the gear-selector rod linkage. Slacken the cable and pry it out of the clip complete with rubber bushing. Tuck the cable behind the brake fluid reservoir.





29. Disconnect the hoses from the expansion tank. Remove the securing bolt, snip through the tie, unplug the connector and lift out the tank.





30. Remove the drive belt for the AC compressor by undoing the locknut and slackening the belt.





31. Place a suitable cover over the RH section of the radiator crossmember. Unplug the connector from the AC compressor and remove the fixing bolts. Disconnect the coolant hose from the water pump and lift the compressor and hose onto the radiator member. It is advisable to secure the compressor by means of a tie.





32. Remove the two clips and snip through the tie securing the Lambda lead to the engine. Unplug the connector at the inlet manifold and drop the lead onto the engine subframe.





33. Remove the torque arm and the top engine mounting.
34. Remove the hose clip and disconnect the bottom radiator hose.





35. Remove the turbo delivery pipe.





36. Remove the nuts securing the exhaust pipe to the turbo unit and lower the pipe.








37. Remove the top fixing bolt and slacken the two bottom ones for the engine oil cooler. Snip through the two ties remove the oil cooler and tie it to the engine.





38. Remove the securing bolt for the power steering fluid reservoir, lower the reservoir and siphon off the fluid.





39. Disconnect the servo inlet hose from the reservoir and tuck the end underneath the inlet manifold. Stand the reservoir on the bulkhead.





40. Disconnect the steering servo delivery hose from the pump. Fit a plug in the end of the hose and tuck the hose out of the way against the bulkhead. Deal with any spillage immediately!





41. Disconnect the vacuum hose to the charcoal canister from the inlet manifold and tuck the hose out of the way.











42. Remove the nuts from the RH engine mountings. Remove the bolt from the LH engine mounting.
43. Raise the car and remove the front wheels.
44. On both sides of the car:








NOTE:
Use a pair of pliers to snip through clips of the non-screw type. Take care not to damage the gaiter. Slacken or remove the clips for the gaiters over the drive-shaft joints.





- Slacken off the bottom bolts securing the MacPherson struts to the steering swivel members and remove the top bolts.





- Pull the steering swivel members to separate the drive-shaft joints.





- Fit protective caps to both halves of the joints.





45. Remove the bottom fixing screw for the cooling fan.








46. Lower the car and remove the top fixing screws for the fan. Unplug the loom and lift out the fan.








47. Attach lifting sling 83 92 409 to the lifting lugs on the engine such that the centre of gravity is displaced towards the transmission end of the unit. Disconnect the struts from the bonnet (hood) and fit extension pieces 8394439 onto the ends.
48. With extreme care, slowly raise the power train.

NOTE: Pay particular attention to ensure that the following components do not snag:
- Brake lines from ABS unit
- Kickdown cable
- Radiator