To Remove

To remove

1. Place wing covers on the wings and front.

2. Remove the battery cover and the battery.





3. Remove the battery tray.

4. Open the expansion tank cap.

5. Remove the upper engine cover.





6. Remove the crankcase ventilation pipe from the turbo intake pipe. Unplug the connector to the solenoid valve.

7. Remove the mass air flow sensor and the intake hose

8. Remove the by-pass valve with pipe.

9. Remove and move aside the engine lifting eye and the solenoid valve.





10. Remove the turbo heat shield. Remove the turbo intake pipe.

11. Remove the oxygen sensor connector and the cable tie.





12. Remove the two upper nuts on the front exhaust pipe.





13. Man: Lock 4th gear in the gearbox by fitting a 87 92 335 Lock pin. Detach the clamp slightly and pull the selector rod out from the linkage.





14. Remove the nut and washer on the right-hand engine pad.





15. Raise the car and remove the right-hand front wheel.

16. Remove the right-hand belt circuit cover. Remove the fixings for the headlamp position sensor (optional) and move the sensor aside.





17. Remove the right-hand wing liner.





18. Remove the front spoiler shield.





19. Drain the coolant.

20. Place a receptacle under the car and drain the engine oil. Fit the oil plug with a new gasket.

Tightening torque 25 Nm (19 lbf-ft)

21. Remove the oil pipes at the oil filter adapter housing.





22. Remove the front exhaust pipe.





23. Remove the front torque arm.

Man: Undo the bolt on the gearbox and fold up the torque arm.





24. Remove the bolts holding the rear engine mounting to the gearbox.





25. Remove the protective cover between the engine and gearbox.





26. Remove the generator's electrical connection.

27. Undo the crankcase ventilation hose and remove the oil sump. Carefully pry open with a crowbar according to the illustration in order to remove the oil sump.





28. Fit a 83 94 868 Flywheel locking attachment, on the starter ring gear.

29. Place double 83 95 238 Wedge between the oil filter adapter and the subframe as well as between the inboard drive shaft universal joint and the subframe.

Note
Take care of the drive shaft universal joint gaiter.

30. Lower the car.

31. Remove the upper coolant hose from the radiator.

32. Remove the fan cowling connector and the hose clip for the expansion tank hose. Remove the fan cowling.

Aut: Remove the bolt for the oil cooler pipe.





33. Remove the bracket to the right-hand engine mounting and the engine pad.





34. Relieve the belt tensioner and remove the multigroove belt. Mark the direction of rotation on the belt.





35. Remove the generator's lower bolt and the outer lower bolt which screws into the timing cover on the intermediate shaft's bearing bracket.

36. Remove the crankshaft pulley.





37. Remove the oil pump. Use 82 93 086 Circlip pliers dia. 120-200 mm. Retain the cover guide pins.

38. Remove the power steering pump from the mounting and move aside. Secure with a 83 95 212 Strap.





39. Remove the power steering pump's mounting bracket.

40. Detach the hose clips and the hoses on the coolant pump inlet.

41. Remove both longitudinal coolant pipes from the cylinder block.

42. Remove both coolant pipes from the coolant pump.

43. Loosen the coolant pipe bolt (on the turbo) slightly from the coolant pump.

44. Remove the coolant pipe from the coolant pump.

45. Remove the coolant pump retaining bolts.





46. Carefully coax the pump away from the bracket and from the pump's connection sleeve in the cylinder block.

47. Remove the connection sleeve from the cylinder block.

48. Remove the AC bracket right-hand upper bolt which screws into the timing cover.





49. Fit 83 96 178 Lifting eyes with bolt and washers or an M12 nut between the cylinder head and bracket.





50. Connect an engine lift and unload the engine from the wedges.





51. Undo the electrical centre and move it aside. Secure with a 83 95 212 Strap. Take care not to scratch the paintwork.

52. Mark the position relative the washers and remove the left-hand engine pad.

Note
Note the location of the short bolt.





53. Man: Remove the torque rod mounting and ground cable.

54. Lift the engine slightly and remove the belt tensioner.





55. Remove the upper generator retaining bolt and remove the generator.

56. Remove the generator bracket.

57. Remove the timing cover bolts. Move the engine to the left. Raise and lower the engine respectively to gain access to all the bolts. Use a ratchet handle and a Torx 40 bit.





58. Remove the timing cover from below. Move the engine to the left. Use a pry bar and place a wood block between the pry bar and the cylinder head. Raise and lower respectively to remove the cover. Protect the paintwork with fabric tape. Two people are needed.

Note
Take care of the cylinder head gasket.

59. Remove the plug for the chain tensioner and the chain tensioner. Take care of the spring and pin.