To Remove and Fit

The procedure described below applies to a car with the Turbo engine, with intercooler, AC, catalytic converter and water-cooled turbocharger (1988 model).
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 and remove the battery.





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. Use tool 87 91 394, if necessary.





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 ball joint from the lower wishbone and the anti-roll bar.

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. Screw out the tensioner and remove the AC compressor drive belt.
15. Remove the drain plugs from the underside of the engine block and the radiator, and drain the coolant. Remove the oil filler pipe.





16. Disconnect the coolant hoses at:
a) Heat exchanger valve. Note the way they are connected.
b) Expansion tank
c) Thermostat housing





REMOVING THE CABLE HARNESS WITH THE WIRING OF THE LH SYSTEM FROM THE B202 ENGINE

17. Disconnect the cable harness of the LH system at:
a) Air mass meter
b) Throttle switch
c) Injection valves
d) Temperature sensor
e) Earthing points at the lifting lug
f) A/C valve

NOTE: If necessary, use a small screwdriver to release the locking clips on the connectors when disconnecting them.

18. Disconnect the other connections of the cable harness at:
g) Temperature switch of the AC compressor
h) Temperature switch for the AC fan AC temperature sensor
19. Withdraw the disconnected cables of the cable harness, withdraw the harness from the engine compartment and place it on the AC system heat exchanger.
20. Remove the turbocharger delivery pipe.
21. Remove the air mass meter together with the bellows.





22. Remove the air cleaner together with the "snorkel".





23. Remove the intercooler together with the air pipe.





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





24. Remove the intercooler side plate.
25. Remove the ignition coil.
26. Remove the radiator fan for the AC system.





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





28. Disconnect the signal hoses from the solenoid valve.





29. Disconnect the throttle cable and electric cable.





30. Disconnect the vacuum hoses for the brake servo from the intake manifold and the tank vent system from the throttle housing.





REMOVING THE LEFT-HAND CABLE HARNESS FROM THE B202 ENGINE

31. Cut off the straps and release the cable harness for the starter motor, alternator, temperature sensor, etc. on the left-hand side of the engine.
32. Disconnect the cable harness connections at the following points:
a) engine temperature sensor
b) hall sensor
c) shift-up switch
d) alternator
e) starter motor
f) throttle switch (AC)
g) oil pressure sensor
h) knock sensor

Place the cable harness on the radiator cross-member.
33. Release the clips securing the positive cable to the engine. Disconnect the cable from the starter motor and place the cable on the battery bracket.
34. Release the earth cable from the mounting on the timing gear cover.





35. Separate the Lambda sensor cables at the connectors over the right-hand wheel housing. Lay the cables on the engine.





36. Disconnect the hydraulic hose from the slave cylinder. Use tool 8393571. Plug the hose.
37. Disconnect the fuel hoses at the connections to the fuel pipe or to the fuel pressure regulator.
38. Remove the four AC compressor bolts and place the compressor on the heat exchanger.
39. Remove all engine mounting bolts. The through bolt in the left-hand engine mounting is fitted with a spacer sleeve. On cars to US specification, also remove the movement limiters from the front and righthand engine mountings.





RIGHT-HAND ENGINE MOUNTING





FRONT ENGINE MOUNTING





LEFT-HAND ENGINE MOUNTING

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.





40. Secure the lifting yoke to the power unit and lift the power unit so that the left-hand inner universal joint can be separated.





41. Disconnect the steering servo pump return line.





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





43. Lift out the power unit.
Keep the power unit close to the bulkhead to avoid damage 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.
Fit the cooling system drain plugs.
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 end piece to the bottom wishbone and the anti-roll 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. 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: 105-125 Nm (77-92 lb ft)
13. Tighten the exhaust pipe flange bolts.





14. Connect the Lambda sensor connector and secure the cable with straps to the AC hose.





15. Connect the radiator hose to the bottom of the radiator and connect the hydraulic line to the clutch slave cylinder.
16. Connect the battery positive cable to the starter motor.
17. Connect the fuel lines to the fuel distribution pipe and to the fuel pressure sensor.








18. Connect the vacuum hoses for the brake servo to the intake manifold and the tank vent system to the throttle housing.
19. Connect the throttle cable and electric cable.
20. Refit the cable harness to the left-hand side of the engine and connect the cables to:
a) temperature sensor
b) Hall sensor
c) alternator
d) starter motor
e) AC throttle switch
f) oil pressure sensor
g) knock sensor





CONNECTING THE LEFT-HAND CABLE HARNESS TO THE B202 ENGINE

22. Connect the radiator hoses to the expansion tank and the heat exchanger valve.
23. Fit the extra radiator fan for the AC system.
24. Fit the intercooler side plate.
25. Remove the cap from the suction pipe of the turbocharger and fit the intercooler together with the air hose. Fit the cover over the radiator.





26. Connect the solenoid valve signal hoses.
27. Connect the radiator hose to the thermostat housing.
28. Fit the ignition coil and connect the HT lead to the distributor cap.





29. Fit the cable harness and the wiring for the LH system and connect the cables to:
a) AC compressor temperature switch (Fig. g)
b) AC temperature sensor (Fig. i)
c) throttle switch (Fig. b)
d) temperature switch for the AC fan (Fig. h)
e) temperature sensor (Fig. d)
f) earthing points at the lifting lug (Fig. e)
Don't forget the earth connection from the left-hand cable harness
g) injection valves (Fig. c)
h) A/C valve (Fig. f)
30. Fit the oil filler pipe.
31. Fit the air cleaner together with the "snorkel".
32. Fit the air mass meter together with the bellows.
Connect the connector (Fig. a)





CONNECTING THE CABLE HARNESS TO THE B202 ENGINE

33. Fit the turbocharger delivery pipe between the intercooler and the throttle housing.
34. Fill the steering-servo reservoir with Texaco Power Steering Fluid 4634 or equivalent.
35. Fill the cooling system with coolant and pressure test it.
36. Fit the battery and connect the cables.
37. Fit the bonnet and connect the hose for the windscreen washers.
38. Start the engine, check the various functions and check that none of the connections are leaking.