To Remove Power Unit

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, the description should be adjusted to suit each individual case.





PROCEDURE
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 it leaning 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.





12. Separate the universal joint on the right-hand side, move the drive shaft forward of the universal joint driver and support it in this position.





13. Release the 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 AC compressor drive belt.
15. Remove the drain plugs from the underside of the engine block and radiator, and drain the 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.

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.





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 fuel return hose (3)
- the hose for the control pressure regulator and fuel-boosting valve (4)





f. Disconnect the fuel pipes from the 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 vacuum tank system from the throttle housing.





24. Release the oil dipstick pipe.
25. Cut away 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 cross-member.





26. Disconnect the coolant pipes to the turbocharger 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 93 571. Plug the hose.





28. Disconnect the coolant hose from the bottom of the radiator.
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 Lambda sensor cable at the connector over 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 right-hand engine mountings.

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





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.