Removal

WARNING:
^ Numerous electrical leads, hoses, cables, etc. are secured by plastic cable ties.
^ After these ties have been pulled tight, the ends are cut off, often leaving sharp edges.
^ Bear this in mind, during service procedures, to avoid these sharp edges, which could be the cause of cuts and scratches on your hands.





NOTE: Step numbers below refer to numbers used in the illustrations.

1. Drape protective covers over the body components to protect the paintwork, then remove the battery.
2. Open the drain plug and drain the coolant.
- Remove the filler cap on the expansion tank to speed up the process.
3. Remove the air cleaner complete with hoses.
4. Detach the throttle cable and position it aside.
5. Disconnect the cruise control cable from the throttle body, unplug the cruise control connector, undo the retaining bolts and remove the cruise control unit complete with cable.
6. Using fuel line separation tool No. 83 94 702, or equivalent, disconnect the fuel hoses and plug them.
7. Disconnect the tank breather hose and position it to one side.
8. Remove the pressure sensor and place it on the engine (turbo).
9. Disconnect the vacuum hose for secondary air injection (as equipped) and disconnect the brake servo vacuum hose from the intake manifold.
10. Remove the boost pressure control (BPC) and place it on the engine.
11. Relieve the belt tensioner of strain, using a ratchet handle extension, and insert a 6 mm, or equivalent, drill in the hole as shown.

CAUTION: Exercise the utmost care to ensure that the belt tensioner does not break at its end position.

12. Remove the servo pump from the bracket and set it aside.
13. Remove the pressure pipe between the charge air cooler and the throttle body.





14. Remove the coolant hoses.
15. Remove the hose for secondary air injection (as equipped).
16. Unplug the AC compressor connector and remove the compressor's upper retaining bolts.
17. Disconnect the positive lead from the positive terminal block (on the engine) and disconnect the ground cable from the gearbox.
18. Remove the ignition cable and the electrical leads from the ignition coil).
19. Unplug the gearbox connectors and place them on the engine.
20. Disconnect the oxygen sensor lead and (in certain markets) the catalytic converter temperature warning lead.
21. On models with automatic transmission, remove the breather hose from the gearbox and plug the hole.
22. Remove the selector lever cable.
- On models with manual transmission, separate the selector rod.
23. Disconnect the clutch cable.





24. On all models, remove the glove box, fold back the carpet and unplug the control module for the central locking system.
- Remove the wiring for the engine.
25. Pull the wiring through the grommet into the engine bay and place it on the engine. Do not forget the lead running to the BPC valve.
26. Loosen the hub nuts on both sides and raise the car.
27. Remove both front wheels and remove the hub nuts. Remove the brake calipers and hang them from the suspension struts.
- Remove the nut for the end piece, steering swivel member on both sides.
28. Remove the covers in the wheel housings and the spoiler sections.





29. Undo the joint between the front exhaust pipe and the intermediate exhaust pipe.
30. Detach the front exhaust pipe from the turbocharger
31. Remove the catalytic converter from its bracket and take down the exhaust pipe.
32. On models with automatic transmission, place a receptacle under the gearbox, disconnect the gearbox oil hoses from the gearbox and plug the holes.
- Position the hoses aside.
33. Remove the pipe between the turbocharger and the charge air cooler.
34. Disconnect the oil hoses from the oil cooler and plug them.





35. Position a lifting table under the car so that the supports on the table are directly under the front engine mountings and gearbox.
- Remove the bolts retaining the sub-frame and the front engine mountings.
36. Lower the lifting table slightly and with it the power train and sub-frame.
- Undo the end pieces and drive shafts on both sides.
37. Remove the AC compressor and hang it from the tow-rope attachment eye.
38. Lower the lifting table fully and remove the rear engine mounting from the gearbox and then remove the sub-frame.