Removal

WARNING: A large number of electrical leads, hoses etc. are secured using plastic cable ties. When these ties have teen pulled tight, the excess length is cut off which may leave a sharp end at the fixing points. Beware of the danger of injury due to these sharp edges on the ties.





1. Drape the fenders with protective covers and remove the engine covers.
2. Undo the connectors and remove the battery.
3. Unhook the front electrical distribution box from the battery shelf.
4. Disconnect the cruise control cable from the lever.
5. Remove the positive terminal block from the battery shelf an take off the clamp for the positive lead. Pull the vacuum hose from its clamps on the battery shelf.
6. Remove the cable conduit fastenings and unbolt the battery shelf.
7. Raise the battery shelf slightly and unplug the electrical connector from the cruise control.
8. Remove the battery shelf with cruise control module and cable.





9. Release the throttle cable from the bracket, snap out the control rod, release the bracket and fold it to one side.
10. Unfasten the hose clamps between the inlet pipes and the intake manifold and between the resonator and the mass airflow sensor and raise the inlet pipes somewhat. Disconnect the vacuum hoses and the electrical connectors and remove the pipes complete with the resonator. Unfasten the secondary air injection hoses from the check valves and cut the cable tie at the resonator bracket.





12. Remove the seal from the detachable bulk-head plate, remove the cover and detach the washer hoses.
13. Unfasten the fuel pipe clamps from the detachable bulk-head plate, undo the bolts and lift up the plate.
14. Unplug the MOTRONIC control module connector and part the engine wiring harness. Pull the wiring through to the engine compartment and remove the detachable bulk-head plate.





15. Unplug the lead from the torque arm engine mounting.
16. Lift off the power steering servo ok reservoir and remove the torque arm.
17. Release the load from the belt tensioner by turning the tensioner pulley forward in the car using a 15 mm wrench. Move the belt to one side.
18. Unfasten the power steering servo pump and remove the clamp from the servo pipe. Move the pump and the reservoir to one side.
19. Unfasten the gear-selector cable (automatic transmission).
20. Disconnect the rear oxygen sensor and release the electrical connectors from the bracket.
21. Place a collecting tray under the engine and disconnect the oil hoses from the transmission (automatic transmission). Plug the hoses and install the bolts in the transmission.
22. Disconnect the fuel hoses and remove the fixing.
23. Ease the expansion tank lid.





24. Raise the car slightly and remove both front wheels.
25. Unfasten the steering knuckle housings from the MacPherson struts and remove the clamps around the inner universal joint gaiters. Pull the universal joints apart and install covers over the halves.
26. Raise the car further and detach from the cylinder block the clamp holding the leads for the oxygen sensor, the knock sensor and the crankshaft position sensor.
27. Unfasten the oxygen sensor, the knock sensor and the crankshaft position sensor and unplug the electrical connectors from the bracket.
28. Part the exhaust pipe at the front joint, undo the nuts between the exhaust manifold and the front exhaust pipe and take down the front exhaust pipe.
29. Remove the center air shield, place a collecting tray under the engine and drain the coolant.
30. Loosen the lower retaining bolt and the upper retaining bolts on the A/C compressor. These can be accessed from underneath (A/C). They cannot be removed in this position.
31. Draw the oil hoses forward (automatic transmission).





32. Lower the car and detach the upper radiator hose from the engine.

NOTE: There is a lot of coolant left in the hose. Leave the collecting tray under the engine.

33. Detach the lower radiator hose from the engine and draw the hose forward. Remove the hoses to the heat exchanger in the cabin.
34. Remove the hose from the expansion tank and lift up the power steering servo pump and the oil reservoir.
35. Remove the brake servo vacuum hose from the intake manifold.
36. Detach the positive lead from the positive terminal block and remove the grounding lead from the gearbox.
37. Undo the remaining bolts on the A/C compressor and take out the upper bolts (A/C).





38. Unfasten the rear and right-hand engine mounting and install extender 83 94 439, or equivalent on the engine hood gas springs.
39. Hook lifting yoke 83 92 409, or equivalent onto an engine lift and the engine and remove the left-hand engine mounting.
40. Lift the power train a short way and remove the resonator bracket.
41. Remove the power train from the car.