To Remove

IMPORTANT: Cables, hoses, leads, etc. are secured with plastic cable ties. After being tightened, the excess part of the cable tie is cut off, resulting in more or less sharp ends remaining at the point of securement. Therefore, care must be taken to avoid injury.

1. Place the car on a lift.
2. Place wing protectors over the wings to prevent soiling and damage to the paintwork.





3. Remove the cover over the intake manifold, alternatively the resonator, together with hoses and mass air flow sensor.
4. Detach the battery leads from the battery.
5. Remove the battery.





6. Engage the gear and remove the plastic plug in the gearbox. Lock 4th gear in the gearbox by inserting locking pin 87 92 335.
7. Loosen the clamp securing the selector rod to the linkage in the gearbox from above.





8. Lift the gear lever boot. Engage 3rd gear so that the selector rod disengaged from the link and insert locking pin 87 92 335 into the gear lever housing.
9. Depress the clutch pedal about 50 mm with a brake bracket. This prevents the brake fluid from flowing out of the reservoir.





10. Remove the locking clip on the slave cylinder and disconnect the delivery pip'





11. Unplug the connector for the reversing lights.
12. Disconnect the positive cable on the battery.
13. Remove the 3 upper gearbox bolts.





14. Unplug the connector(s) to the oxygen sensor and release it/them from the clamps.
15. Take the weight off the engine and gearbox with rifling beam 83 94 850. Place the beam on the wheel housings so that it rests on the edges of the wings.
16. Raise the car.
17. Remove the front wheels.
18. Remove any clamps on the oxygen sensor cable.





19. Remove the front exhaust system by first undoing the flange on the turbo and then undoing the rear mounting. It is important that the exhaust system is removed in this way as the flexible bellows may other wise be damaged. Be also careful with the oxygen sensor(s).
20. Remove the air shields and belt-circuit cover in the right-hand wheel housing.





21. Detach the suspension arm end pieces on both sides. Use puller 89 96 696.
22. Remove the two nuts on the rear engine mounting and the two center bolts on the subframe.
23. Place the lining trolley with front and rear holders with parent fixture 83 94 801 under the subframe. Raise the lifting trolley against the subframe.
24. Remove the remaining bolts securing the subframe. There are washers on the rear mountings, take care of them.
25. Lower the trolley lid and push it to one side.





26. Remove the oil drain plug and drain the oil from the gearbox. Screw in the drain plug again.
Tightening torque: 50 Nm (37 ft. lbs.)





27. Pull out the left drive shaft with removal tool for drive shafts 89 96 654. Suspend the shaft with strap 83 95 212 and fit protective plugs 87 92 244, in the gearbox.





28. Remove the splash plate by the flywheel.
29. Disconnect the ground leads from the gearbox.
30. Undo the bolts in the engine/gearbox mating face that are accessible from below with the exception of the front one.
31. Undo the two left-hand engine mounting bolts from the body.
32. Remove the mounting from the gearbox.
33. Lower the car and lower the whole drive unit approx. 5 cm.





34. Raise the car and fit lining tool 87 92 608, to a single-column jack.





35. Lining tool 87 92 608 seen from the side.
36. Adjust the lining tool so that it is centered in line with the gearbox center and mating face. Connect the lining tool to the gearbox
37. Remove the last bolt between the engine and the gearbox.
38. Remove the rear engine mounting
39. Pull out and lower the gearbox bracket from the gearbox.

WARNING: Take care not to tip the jack.

40. Lift the gearbox from the pillar jack with and engine lift and undo the lifting tool from the gearbox.