Removal

NOTE: The method described applies to the car when equipped with AC, automatic transmission, catalytic converter and a hydraulic automatic belt tensioner for the auxiliaries belt.

CAUTION: 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 chaffing.





1. Raise the car on a lift and remove the front wheels. Remove the fender liners from the RH fender. Remove the middle infill panel from under the spoiler.





2. Unscrew the drain plug from the radiator and drain off the coolant. To speed the process, lower the car and remove the filler cap from the expansion tank.
3. Disconnect the battery leads and remove the battery.





4. Make access for removal of the battery shelf as follows:
^ Unbolt the steady bar for the ABS unit
^ Unplug the three connectors for the DI system wiring loom and release the clips for the leads from the bracket attached to the battery shelf.





^ Disconnect the battery positive lead from the terminal block and remove the clip from the shelf. Remove the terminal block.








^ Disconnect the battery negative lead from the grounding point on the fender. Remove the battery shelf and tuck the leads out of the way.

CAUTION: To avoid electrical problems and to maintain a high level of reliability, the connectors in the engine bay are designed to be a tight fit. Consequently, they are sometimes difficult to separate. Never try to separate the connectors by pulling on the leads.

5. Unplug the connector for the Direct Ignition System (DI) wiring loom and the connector from the knock detector in the block (underneath the inlet manifold).





6. Slacken the clip and disconnect the top radiator hose.
7. Make access for removal of the air intake at follows:





^ Unplug the connector from the air mass meter
^ Undo the steady bar for the air-intake silencer





^ Release the toggle clips on the air cleaner





^ Undo the hose clip at the throttle housing. Lift off the air intake complete with silencer, air mass meter and rubber elbow.





8. Unplug the connectors for the washer-fluid level sensor and pump. Unplug the hose from the tee piece and plug the end of the hose (e.g. with a suitably sized bolt). Undo the two securing screws and lift out the reservoir.





9. Remove the clip, lift up the throttle lever and disconnect the cable from the linkage.





10. Disconnect the fuel return hose from the fuel-pressure regulator and tuck the end of the hose up against the false bulkhead panel.
11. Place a piece of rag or absorbent paper under the connection, and disconnect the fuel supply hose from the fuel-injection rail. Pull out the end of the hose and tuck it out of the way.





12. Remove the cover over the space behind the false bulkhead panel.
13. Remove the rubber moulding from the edge of the panel.








14. Undo the clip securing the engine wiring loom to the bulkhead panel. Undo the securing bolts and lift out the false bulkhead panel.





15. Unplug the connector in the engine wiring loom and tuck the loom away on top of the engine.





16. Unplug the connector for the road-speed sensor lead.
17. Pull the cable out of the grommet in the bottom of the bulkhead and tuck the lead away on top of the engine.





18. Disconnect the heater-box hoses from the cylinder head and tuck them away behind the brake fluid reservoir.





19. Unscrew the clip securing the kickdown cable to the pipe from the steering servo pump.





20. Clean the surrounding areas and disconnect the hoses from the oil cooler for the automatic transmission. Block off the ports in the transmission case and the fittings on the ends of the hoses. Secure the hoses to the radiator crossmember.
21. To avoid the leads being damaged when the powertrain is lifted out of the car, unplug the connector from the brake fluid reservoir.





22. Remove the nut from the gear-selector rod linkage.





23. Slacken the cable and pry the rubber bushing out of the clip. Tuck the cable behind the brake fluid reservoir.





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





25. Use a spanner to release the tension applied by the belt tensioner and apply a hard upward pull on the belt. As soon as the belt is slack enough, install locking pin 83 94 488 to the tensioner. Ease the belt off the A/C compressor pulley.





26. Install a protective steel panel or the like over the oil cooler and cover the RH section of the radiator crossmember with rags. Unplug the connector from the AC compressor, undo the securing bolts end lift the compressor onto the radiator crossmember. Secure the compressor for the time being by means of a tie or the like.
27. Disconnect the top radiator hose from the water pump. Undo the clip and disconnect the bottom radiator hose from the pump.





28. Disconnect the Lambda sensor by unplugging the connector underneath the inlet manifold.








29. Snip through the ties securing the servo hoses, charcoal-canister hose and wiring loom to the top torque arm. Disconnect the radio-suppressor (ground) lead from the torque arm fixing and remove the arm.





30. Disconnect the hose to the charcoal canister from the inlet manifold and tuck it out of the way.





31. Unbolt the exhaust pipe from the exhaust manifold.





32. Unplug the connector from the oil-level sensor and place the lead along the edge of the fender.








33. Remove the top securing bolt and slacken the two bolts at the bottom of the oil cooler. Snip through any ties and tie the cooler to the engine.
34. Undo the securing bolt for the power-steering fluid reservoir, lower the reservoir and siphon off the fluid.
35. Disconnect the servo hose from the reservoir and tuck the end underneath the inlet manifold. Stand the reservoir on the bulkhead.





36. Raise the car and disconnect the steering servo delivery pipe from the pump. Use a second spanner across the flats to stop the fitting turning. Install a plug in the end of the pipe and deal with any spillage immediately. Remove the pipe clip from the support bearing bracket rear engine mounting.





37. Remove the nuts from the engine mountings on the RH side.

NOTE: Use a pair of pliers to snip through clips of the non-screw type. Take care not to damage the boot.

38. On both sides of the car:








^ Unscrew or remove the clips for the boots 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 away the steering swivel members to separate the drive-shaft joints.





^ Install protective caps to both halves of the joints.
^ Lower the car.
39. Unbolt the LH engine mounting.





40. Disconnect the struts from the hood and install extension pieces 83 94 439 onto the ends.








41. Attach lifting sling 83 92 409 to the eyes on the engine. With extreme care, slowly raise the power train. Pay particular attention to ensure that the following components do not snag:
In the engine bay:
^ ABS unit
^ Kickdown cable
^ Cooling fan
On the powertrain:
^ Steering servo pump
^ Alternator pulley