Removal
Special Tools
999 2810
999 5428
999 5462
999 5474
999 5488
999 5533
Note! From autumn 1993 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.
Removing engine
Drain coolant
Remove expansion tank cap.
Raise the car.
Automatic: Remove air guide under engine.
Open the engine and radiator nipples. Thread hoses onto the nipple to collect the coolant.
Disconnect the lower charge air pipe from Charge Air Cooler (CAC) lower sleeve connector.
Close the nipples.
Remove
- front wheels
- tie rod end from left stub axle
- the three nuts holding the ball joint to the control arm on the left-hand side
Remove
- ABS cable and brake pipe/hose bracket screw
- left drive shaft, a gimmy bar 999 5462 must be used to release the drive shaft (the snap ring may be damaged otherwise)
Remove
- tie rod end from right stub axle
- the three nuts which hold the ball joint to control arm on right-hand side
- right drive shaft and intermediate bearing cap from drive shaft, carefully place it on the steering servo pipes
- the two screws for the right engine mounting (bend the right fender liner to one side slightly first)
- the transmission torque rod screw
Note! Install sealing plugs 999 5488 in the holes left by the drive shafts.
Remove
- front exhaust pipe lower nut and screw from the bracket
- speedometer connector
- front and rear engine mountings lower screws.
Lower car to a comfortable working height
Remove
- battery
- battery shelf, with a clutch slave cylinder for the cruise control (which is removed from the shelf and put to one side)
- fresh air intake hose from air intake to Air Cleaner (ACL) housing
- ignition cable between distributor/ignition coil
- throttle pulley cover
- throttle cable from throttle pulley
Disconnect hoses/connectors:
- Disconnect inlet hose from the Turbocharger (TC) to Air Cleaner (ACL) at both ends
- disconnect the hose for the PTC valve and connector
- disconnect connector from throttle sensor
- disconnect idle air trim connector.
- disconnect Turbocharger Control Valve (TCV) connector
Remove the Air Cleaner (ACL) housing disconnect Mass Air Flow (MAF) sensor connector
Disconnect and raise Air Cleaner (ACL) housing.
Remove two Turbocharger Control Valve (TCV) bracket screws
Remove
- torque rod from bracket and cowl panel.
- ground strip from cowl panel
- the two heater hoses from the cowl panel
- Heated Oxygen Sensor (H02S) connector and clips ((USA variants are equipped with two Heated Oxygen Sensors (H02S))
- brake servo hose from engine or separate it under the Air Cleaner (ACL) housing
Remove the engine Coolant Fan (FC)
Remove relays from the fan shroud, separate the relay and fan connectors, put wiring to one side.
Remove the air duct for cooling the control module box.
Disconnect both canister hoses and valve from the radiator.
Remove the four fan shroud screws and the upper charge air pipe from the turbocharger. Slide the fan shroud slightly backward and remove the upper fan shroud. Remove upper charge air pipe.
Remove fresh air intake from radiator and disconnect vacuum hoses to Turbocharger instruments and EGR- regulator.
Caution: Protect the radiator with a hard sheet or similar. Alternative protection 999 5474.
Remove
- idle air trim together with lower charge air pipe
- lower radiator hose, from engine
- the protective cover over the starter motor
- battery negative lead, from engine and wheel arch (also from transmission on automatic)
Car with manual transmission:
- clutch slave cylinder snap ring
Note! (Ensure that the piston does not slide out)
- slave cylinder from gear box
Remove
- air cleaner housing bracket. (carefully put air cleaner bracket and clutch slave cylinder to one side so that they are not separated.)
Manual:
Remove: gear selector cables from their mountings on the transmission (mark up cable positions).
Remove the rubber mounted section of the gear selector cable mounting.
Automatic:
Disconnect connector and remove gear selector cables from the transmission (and mark up the cable positions).
Disconnect the two oil cooler hoses from the radiator, using victory clip tool.
Remove
- upper radiator hose from thermostat housing
- expansion tank
- auxiliaries belt
- the six power steering pump screws (disconnect the temperature sensor cable from the bracket on the power steering pump)
Hint: Allow power steering pump to remain on hose.
Disconnect the two oil cooler pipes from the radiator.
Remove Air Conditioning (A/C) compressor
Remove Air Conditioning (A/C) compressor without removing hoses and put onto sub-frame. (Remove the screws on the right-hand side by bending the fender liner a little to one side.)
Remove the cable duct bracket screws
Remove the cable duct bracket screws
Remove starter motor support bracket.
Remove
- the protective cover over the fuel rail
- injector connectors
- fuel line clip (upper/lower)
- engine ground strip
Remove the fuel rail
Install holder 999 5533 (5 x) on the injectors
Disconnect fuel pressure regulator vacuum hose.
Lift up and put fuel rail with injectors to one side.
Caution: Take care not to damage the injector nozzles and fuel needles.
Expose the engine cable harness
Disconnect all connectors and clamps from engine.
Note! Note all the cable harness mountings positions.
1. Thermostat
2. Generator (GEN)
3. Air Conditioning (A/C) if installed
4. Ground terminal
5. Oil pressure switch
6. Oil level sensor
7. Starter motor (all)
8. Knock Sensor (KS)
9. Ground terminal
10. Ground terminal
11. Throttle housing switch
12. Idle air trim
13. Flywheel sensor
14. Injectors
15. Camshaft Position (CMP) sensor
16. Back-up (reversing) lamp switch
17. Mass Air Flow (MAP) sensor
18. Vehicle Speed Sensor (VSS)
19. Heated Oxygen Sensor (HO2S) (automatics x 2)
20. PTC element
Remove engine with transmission
Lift power steering pump and put it to one side.
Remove front engine pad when lifting.
Remove engine, use lift yokes 999 2810 (in version with lifting arm 999 5428.
Adjust lifting angle during the lift (a relatively large angle is required).
Automatic: Remove Turbocharger (TC) oil cooler hoses with valve, from oil pan right side.
Caution: Check carefully that the driveline is clear of the bodywork and other optional extras.