Removal

NOTE: The engine-transmission unit is removed as a unit from below.





Assembly Note for Removing / Installing Engine:

When removing and installing the engine and transmission assy., it is recommended to allow a constant clearance of 60 cm between drive shaft and shop floor. Have the height of the lifting platform adjusted accordingly by a helper.

Removal

1. Raise vehicle on jacking points.
2. Disconnect ground cable from battery.

NOTE:
- Permanent positive voltage at DME control unit
- Since the Motronic M5.2 includes several adaptive systems, a permanent positive voltage is present at terminal 26 of the DME connector.
- When the connector is disconnected from the control unit or when the vehicle battery is disconnected, the engine must run for 250 seconds before the first adaptation phase occurs after reconnecting.
- In addition, the DME control unit features a volatile fault memory.
The fault memory contents should therefore always be read out before the battery is disconnected.

3. Protect protruding upper lock section in a suitable way, e.g. with a piece of hose (to prevent injury).
- Place rear protective covers in position.





4. Disconnect connector joint, remove A/C compressor from bracket and leave it connected to the hoses.
- The compressor may be placed on a suitable firm support on the right-hand side section.
5. Remove full intercooler and air cleaner assemblies.
- Plug pressure pipes leading to turbocharger.





6. Remove switchover flap and rear heater blower.





7. Take cover off the the engine compartment electrical system.
Disconnect connectors carefully (to avoid breakage).
Retain socket in place when pulling off connectors.




8. Detach the following connectors and pipes/hoses on the left side of the engine compartment:
1 - to carbon canister
2 - To temperature sensor 11 (Cyl. 3) (connector color: white)
3 - To Knock sensor (connector color: green)
4 - Cruise Control connector
5 - To reference mark sender (connector color: black )





9. Pull vacuum line (arrow) for heater control off the connector strip.

NOTE: To facilitate identification, the Fig. shows the connector strip with the engine removed from the car.





10. Disconnect two hose connections for crankcase /oil tank vent.





11. Pull vent hose off the branch piece.
12. Disconnect throttle operating cable.
- Press rubber grommet out of its support.

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

13. Pull oxygen sensor connectors out of bracket, unlatch connectors and disconnect them.





14. Empty Pentosin Reservoir (draw off contents).
- Pull off hoses and catch remaining oil.
- Plug all openings (to avoid dirt ingress).

Left Side (Fuel Return):

Right Side (Fuel Supply):

15. Loosen fuel return and fuel supply lines, using a second wrench to lock.
Drain remaining fuel.





16. Remove rear tray from center console.
- The mounting screw is located below the rubber insert.
- Flip over damping tab.
- Take off locking cover.
- Undo central tube / transmission mounting bolts.

Dismantling Operations With The Vehicle Off The Ground
1. Take off engine and transmission undertray.
2. Detach ball clamps and remove tail pipes from rear mufflers.
3. Remove both rear mufflers.

NOTE: The rear mufflers are held in place by the top support.

4. Detach drive shafts from transmission flange and rest them on the side sections.
- Protect drive shafts against damage, e.g. by using hose sections.
5. Pull rubber sleeve forward onto the gearshift rod coupling and loosen fit bolt.





6. Unscrew both hexagon socket screws of the clamping sleeving and push clamping sleeve forward on the central shaft.





7. Remove hot air hoses, hot air pipes, hot air flaps and front transverse strut.
8. Remove complete stabilizer assembly.





9. Mark position of toe eccentrics (A area).





10. Loosen fastening nut no.
1 (without removing it).
Remove toe eccentric (A area).
Rotate toe control arm 2 towards the outside (detaching it from the cross member).

IMPORTANT: While doing so, the rubber boot of the ball joint must be rotated as well (arrow); otherwise, the boot might get damaged.

11. Detach toe control arm 2 on the other side as well and rotate it downwards.
12. Remove rear cross member (4 fastening screws).





13. Drain engine oil at thermostat housing.
During engine overhauling, also drain oil at crankcase.
14. Detach ground strap between body and starter at lower starter mounting point.
15. Disconnect wire terminal 30 from starter.
16. Disconnect oil return line from gearbox.





17. Detach oil return line (wrench size 36).

18. Detach fastening bracket from servo slave cylinder.

NOTE: The servo slave cylinder is detached later on after lowering the engine/transmission unit (accessible from engine compartment).





19. Loosen hose clamp at oil feed line and collect residual oil.





20. Pre-load car-jack with engine mounting plate and put it in place under the car.

NOTE:
- Observe position of mounting plate.
- Lock levers in horizontal position.
- The supporting blocks of the support plate face downwards.





21. Loosen lower connecting screws central tube/gearbox.
22. Detach gearbox crossmember (6 screws).
23. Remove metal lid of the assembly bores of the engine suspension in the rear engine closing panel und loosen hexagon nuts of engine carriers from below.
To do so, use long socket.
24. Lower engine/transmission unit until central tube rests on the central tube underside tray.





25. In this position, the fastening nuts (2 pcs.) of the servo slave cylinder are accessible from the engine compartment.

26. Lower engine/transmission unit further.
On the right, swing drive shaft and rest it on starter.

IMPORTANT: If the vehicle is put on its wheels, the rear cross member and the two toe control arms 2 must always be fitted to provide the required stability.

NOTE:
- With the servo slave cylinder removed, the clutch pedal must not be operated.
- Attach corresponding note to vehicle!