To Remove

1. Place the car on a lift.

CV: Remove the chassis reinforcement, front subframe.

2. Place a receptacle under the car. Use protective gloves. Remove the plug and drain the gearbox oil. Fit the plug.

Tightening torque, automatic transmission 45 Nm (33 lbf ft)

Tightening torque, manual gearbox 50 Nm (37 lbf ft)





Figure 1

3. Remove the drain plug and drain the engine oil. Fit the plug with a new 0-ring.

Tightening torque 25 Nm (18 lbf ft)





Figure 2

4. Remove the engine assembly, see WIS - 9-3 (9440) - Engine - 4 cylinder petrol - Basic engine - Adjustment/Replacement - Power train removal.

5. Allow the power train to remain on the trolley lift.

6. Remove the cover to the spark plugs.





Figure 3

7. Remove the engine wiring harness using the following method:

7.A. Unplug the connector from the charge air control valve.





Figure 4

7.B. Unplug the connector from the coolant temperature sensor.

7.C. Unplug the engine control module connector.

7.D. Unplug the engine control module connector.

7.E. Unplug the connector from grounding point G7.

7.F. Unplug the bypass valve connector.

7.G. Unplug the throttle body connector.

7.H. Unplug the 4 ignition coil connectors.

7.I. Unplug the connector from the ionization detection module.





Figure 5

7.J. M03: Unplug the connector from the exhaust temperature sensor.

7.K. Unplug the connector from the front heated oxygen sensor.

7.L. Unplug the connector from the rear heated oxygen sensor.

7.M. Unplug the connector from the atmospheric pressure sensor.





Figure 6

7.N. Unplug the connector from the intake manifold pressure sensor.

7.O. Remove the power steering fluid pressure switch.

7.P. Remove the starter motor contacts.

7.Q. Cars with secondary air injection pump: Unplug the secondary air injection pump connector.





Figure 7

7.R. Remove the oil pressure switch.

7.S. Unplug the connector from the crankshaft position sensor.

7.T. Unplug the EVAP canister purge valve connector.

7.U. Unplug the oil level sensor connector.

7.V. Unplug the generator connector.

7.W. Unplug connector H8-9.

7.X. Cars with manual gearbox: Unplug the reverse light contact.

7.Y. Remove the wiring harness retaining bolts. Pull out the wiring harness and lift it aside.

8. Remove the lower charge air pipe.





Figure 8

9. Remove the turbocharger heat shield.

10. Remove the catalytic converter heat shield.

11. Unplug the heated oxygen sensor connectors and lower the cables carefully.

12. Unplug the temperature sensor connector and lower it carefully.

13. Remove the catalytic converter from the cylinder block and the turbocharger. Lubricate the turbocharger studs with rust solvent oil. Lift out the catalytic converter.





Figure 9

14. Remove the hoses from the coolant-cooled oil cooler.

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Figure 10

15. Remove the breather hose on the cylinder head.

16. Remove the turbocharger coolant pipe.





Figure 11

17. Remove the thermostat housing and pipe. Allow the hoses to remain on the thermostat housing.

18. RH side: Tap out the drive shaft from the intermediate shaft with a brass drift and mallet. Lift out the drive shaft.





Figure 12

19. Remove the intermediate shaft from the engine.





Figure 13

20. LH side: Pull out the drive shaft from the gearbox. Prise with 87 92 616 Removal tool, drive shafts. Lift out the drive shaft.





Figure 14

21. Remove the LH drive shaft seal with 87 92 350 Puller, drive shaft seal and 87 91 683 Puller.

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Figure 15

22. Remove the RH drive shaft seal with 87 92 350 Puller, drive shaft seal and 87 91 683 Puller.

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Figure 16

23. Cars with secondary air injection pump: Remove the pipe between the pump and the valve.





Figure 17

24. Remove the starter motor.

25. Remove the coolant-cooled oil cooler.





Figure 18

26. Remove the power steering pump from the cylinder head and move it aside.

27. Cars with automatic transmission: Loosen the 6 bolts holding the torque converter to the driver plate. Turn the engine clockwise with the pulley.

�Q°:

Figure 19

28. Cars with automatic transmission: Detach the plug, press the torque converter toward the transmission and fit holder 87 92 574 to hold the torque converter in place when removing the transmission.

29. Fit lifting eyes, B207, 83 96 178.





Figure 20





Figure 21

30. Secure the engine with an engine lift.

31. Remove the torque arms from the oil sump and gearbox.

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Figure 22

32. Raise the engine and remove the lower gearbox retaining bolts.

33. Carefully lower the engine onto a pallet, for example.

34. Remove the upper gearbox retaining bolts.





Figure 23

35. Fit 87 92 442 Lifting cable to the gearbox and raise the gearbox slightly. Remove the gearbox from the engine.

36. Raise the engine and fit 83 94 751 Holder. Fit the engine to the floor stand 78 74 878.

37. Remove the turbocharger oil delivery pipe.





Figure 24

38. Remove the turbocharger oil return pipe.

39. Remove the lower turbocharger attachment bracket.

40. Remove the crankcase ventilation hose from the camshaft cover.

41. Remove the generator.





Figure 25

42. Cars with secondary air injection pump: Remove the pump with bracket.

43. Remove the lower intake manifold attachment bracket.





Figure 26

44. Remove the crankshaft position sensor.

45. Remove the bolt from the dipstick pipe.

46. Fit the flywheel locking attachment 83 94 868 50 that the flywheel/driver plate are locked.

47. Cars with manual gearbox: Remove the bolts holding the pressure plate and remove the clutch and driven plate hub.

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Figure 27

48. Cars with manual gearbox: Remove the flywheel.

Cars with automatic transmission : Remove the driver plate.





Figure 28

49. Remove the flywheel locking attachment 83 94 868.

50. Remove the ignition coils.

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Figure 29

51. Remove the bracket.

52. Remove the ground cable from the camshaft cover.

53. Remove the camshaft cover.

54. Remove the engine mounting bracket.





Figure 30

55. Remove the belt tensioner.

56. Reset the crankshaft. Remove the crankshaft pulley with 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207.

57. Remove the timing cover and gasket.





Figure 31

58. Remove the crankshaft seal.

59. Remove the timing chain tensioner.

60. Remove the plug from the cylinder head.

61. Remove the upper bolt from the chain guide near the intake side.





Figure 32

62. Remove the upper timing chain guide rail.

63. Remove the lower chain guide bolt. Pull the chain guide down. Detach the lower section of the chain. Remove the sprocket.

64. Remove the camshaft sprockets. Use a wrench to grip the camshaft flats when the bolts are loosened. Lift up the chain.

65. Remove the tensioner guide by lifting it up. Inspect the condition of the guide. Replace if necessary.

66. Remove the balancer shaft chain tensioner.





Figure 33

67. Remove the balancer shaft chain guide bars.

68. Remove the balancer shaft chain, sprocket and wedge.

69. Remove the cylinder head in the order shown in the illustration.





Figure 34

70. Remove the oil filter cover and oil filter.





Figure 35

71. Remove the dipstick pipe.

72. Lower the cylinder block from 78 74 878 floor stand and remove 83 94 751 holder.