Removal

NOTE: The method described applies to a car equipped with water-cooled turbo, intercooler, AC, automatic transmission, catalytic converter, two-stage cooling fan and automatic belt tensioner and engine in car. The procedure will obviously need to be adapted as appropriate to suit cars to different specifications.

NOTE: A redesigned cylinder head has been introduced as a running change on B202 (16-valve) engines starting with Engine Number J082586. The new cylinder head has oil passages drilled into the head casting, thereby eliminating the external oil pipes and fittings previously used to supply oil to the camshafts and lifters. The new cylinder head has also been introduced into the spare parts system for replacement use on earlier 16-valve engines when existing stocks are depleted. No special procedures or parts are required to install the new design head on an earlier car. The same cylinder head bolts and bolt torque specifications are used.

*** FOR ADDITIONAL INFORMATION NOT INCLUDED HERE, REFER TO TSB #08881067, DATED AUGUST, 1988 ***


1. Raise the car on a lift and remove the right front wheel.





2. Remove the front section of wing liner.





3. Remove the middle infill panel from under the spoiler. Remove the plug and drain the coolant. Remove the securing screw in the bottom of the radiator fan.





4. Lower the car, disconnect the negative (-) battery lead and cover the terminal pole on the battery.





5. Disconnect the hoses from the expansion tank. Remove the expansion tank through-bolt, snip through the tie, unplug the connector and lift out the tank.





6. Remove the torque arm from the top engine mounting.





7. Remove the power-steering fluid reservoir, snip through the tie around the hoses to the charcoal canister and move the reservoir out of the way.





8. Slacken the AC-compressor drive belt and remove the belt.





9. Unplug the connector from the AC compressor and unbolt the compressor from the bracket. Remove the bottom hose clip on the coolant hose (at the water pump) and place the compressor complete with hose and belt tensioner on the radiator crossmember. Place a cloth or other suitable protection underneath the compressor to protect the crossmember.





10. Remove the compressor bracket.





11. Unplug the two connectors from the Lambda sensor (at inlet manifold), remove the clips on the block and snip through the tie at the lifting lug. Place the lead on the engine subframe.





12. Remove the nuts securing the exhaust pipe to the turbo unit and lower the pipe.





13. Remove the solenoid valve and tuck it down towards the Air Flow Meter/Sensor.





14. Remove the securing screws in the top of the radiator and unplug the connectors. Lift out the radiator.





15. Remove the turbo delivery pipe.











16. Disconnect the turbo inlet hose from the compressor and disconnect the solenoid-valve hoses ("C" from the compressor; "W" from the wastegate valve). Disconnect the top coolant hose from the engine and the rubber socket connector for the turbo delivery pipe from the throttle housing. Tuck the hose out of the way.





17. Remove the lower cooling pipe for the turbo.








18. To gain access to the top cooling pipe for the turbo:
- Disconnect and tuck out of the way the crankcase breather hose/preheater hose for the throttle housing.
- Remove the banjo fitting at the turbo compressor.
- Remove the nut on the exhaust manifold.
- Remove the hose clip on the hose underneath the inlet manifold.
- Remove the cooling pipe and hose.

18. Alternative method:
- Disconnect and tuck out of the way the crankcase breather hose/preheater hose for the throttle housing.
- Remove the hose clip and disconnect the hose and cooling pipe.

NOTE: The cooling pipe thus remains attached to the turbo unit when the unit is removed.





19. Remove the clip on the transmission case, disconnect the oil supply pipe from the turbo unit and move the pipe out of the way.





20. Remove the turbo compressor bracket.
21. Remove the top fixing bolts for the oil return pipe, remove the bottom ones and slide the end of the pipe further into the sump.





22. Unbolt and lift oft the exhaust manifold and turbo assembly. Hold the lubricating oil feed pipe out of the way as the assembly is removed.
23. Disconnect the crankcase breather hoses and vacuum control unit and tuck them out of the way.





24. Remove the inspection cover and detach the HT leads from the plugs.





25. Remove the distributor, tucking it and the leads out of the way.





26. Unplug the lead from the temperature sensor and disconnect the heater-box hose from the thermostat housing.





27. Remove the fixing for the fuel-pressure regulator bracket and swivel the bracket complete with sernsor and hoses out of the way.





28. Remove the bolts securing the torque-arm bracket to the cylinder head.
29. Slacken off the top fixing bolts for the inlet-manifold steady bars, one on either side.
30. Remove the bolts securing the inlet manifold to the cylinder head.





31. Remove all the bolts and lift off the camshaft cover.

NOTE: Cars with two-section in let manifold:
- Disconnect the AIC-valve hose.
- Disconnect the crankcase breather hose.
- Remove the dipstick tube.
- Detach the inlet manifold from the hoses, tip it out of the way and secure the hoses with ties.








32. Line up the "O" degree mark on the flywheel with the timing mark on the end plate and ensure that the timing marks on the camshafts are also in line.








33. Remove the chain tensioner. Remove the camshaft sprockets.





34. Remove the two bolts securing the timing cover to the cylinder head from underneath.
35. Remove the cylinder head bolts (ten Torx bolts).





36. Soak up any oil before removing the cylinder head. Make sure that the chain is positioned such that the pivoting chain guide will not obstruct removal of the head. Lift off the cylinder head.