Removal

NOTE:
^ Step numbers below refer to numbers used in the illustrations.
^ The method described applies to removal of the power train with A/C and automatic transmission or manual gearbox.

WARNING:
^ A large number of electrical leads, hoses, etc. are secured by plastic cable ties.
^ When these cable ties have been pulled tight the excess length is usually cut off, often leaving a more or less sharp edge on the plastic.
^ Bear this in mind when securing cable ties and avoid leaving sharp edges that could do damage by chafing or scratch bare hands.

1. Drape the fenders with protective covers and remove the battery.
2. Unscrew the drain plug for the coolant.
- Remove the filler cap from the expansion tank to speed up the process.
3. Remove the two engine covers.
- Remove the complete air cleaner assembly.
- To do this, disconnect the hose clip, unplug the two connectors and remove the retaining screws.
4. Disconnect the throttle cable and position it aside.
5. Remove the cruise control unit complete with cable.
- First expose the ball in the throttle and release the cable from the clip in the bulkhead partition.
- Disconnect the electrical connections on the cruise control system and remove the retaining screws.





6. Remove the two fuel connections and plug them.
7. Disconnect the tank breather hose and position it aside.
8. Disconnect the brake servo vacuum hose.
9. Remove the top radiator hose.

NOTE: It is secured to the fan cowl by a clip.

10. Remove the radiator fan cowl.
- Unplug the two connectors, disconnect the power steering pipe from the radiator member and battery tray.
- Remove the fan cowl retaining screws.
- Carefully lift out the fan cowl.
11. This step is not applicable to this model.
12. Disconnect the bottom radiator hose from the engine.





13. Slacken the belt pulley bolts slightly.
- Relieve the belt of tension and move it aside.
14. Remove the power steering pump pulley.
- Remove the two power steering pump retaining bolts and lift out the pump.
15. Unplug the A/C compressor connector and undo the clip.
- Remove the A/C compressor's upper retaining bolts.
16. Disconnect the radiator hose connected to the throttle body at the expansion tank.
17. Disconnect the hoses connected to the heater core at the engine and position them aside.
- Also disconnect the radiator hose from the expansion tank at the engine.





18. On models with automatic transmission, unplug the two wiring harness connectors behind the battery and place the cables on the power train.
- On models with manual gearbox, remove the reversing light switch.
19. On all models, disconnect the positive cable from the positive terminal.
20. Disconnect the grounding connection on the gearbox and tuck the cable out of the way.
21. On models with automatic transmission, remove the breather hose from the automatic transmission and plug the hole in the transmission casing.
22. Undo the nut securing the selector lever cable and remove the cable.
- n models with manual gearbox, engage 4th gear, separate the selector rod and engage 3rd gear by means of the gear lever.
- Disconnect the clutch cable.)
23. On all models, remove the following engine wiring harness:
- From inside the car:
- Remove the glove box and air ducts and fold up the carpet.
- Remove the knee shield.
- Remove the engine wiring harness.
- From the engine bay:
- Pull the wiring harness through the lead-through into the engine bay and place the wiring on the engine.





24. Slacken the hub centre nuts on both sides and raise the car.
25. Remove both front wheels and remove the hub centre nuts.
- Remove the brake calipers and suspend them from the MacPherson struts.
- Remove the nut securing the steering swivel joint on both sides.
26. Remove the cover in the right-hand wheel housing and the spoiler sections.
27. Raise the car higher and unplug the oxygen sensor connectors.
- Remove the front exhaust pipe.

NOTE: If the front exhaust pipe need not be removed for the repair, separate the joint between the front and centre exhaust pipe sections.

28. Undo the bolt in the AC compressor bracket.
- The bolt cannot be removed in this position.
29. On models with automatic transmission, place a receptacle under the transmission, remove the oil pipes from the transmission casing and plug the holes.
30. On all models, run lifting trolley tool No. 83 94 739, or equivalent, under the car and arrange it so that the holders on the trolley are directly below the front engine mountings and the gearbox and abut against them.
- Remove the subframe retaining bolts.
- Remove the front engine mountings from the body.
31. Lower the lifting trolley about 25 centimeters and with it the subframe and power train.
- Make sure that the steering swivel joints come away and lift out the drive shafts.
32. Remove the AC compressor and suspend it from the towrope attachment eye by means of cable ties.
33. Lower the lifting trolley all the way down and remove the nut in the rear engine mounting.
- Pull the subframe away to the rear.