Removing
1. Disconnect the wire "masses" (–) batteries.
Attention! This erases the anti-theft code of the radio.
2. Remove fan shroud (7) and place on top of the fan.
3. Remove air hose (21), by unfastening the clamp.
4. Disconnect cable duct (3) from the front wall of the body.
5. Remove the bottom cover of the engine compartment.
6. Drain the coolant.
7. Drain the engine oil.
8. Unscrew the front exhaust pipe from the manifold.
9. Unscrew the exhaust pipe holder brackets from the gearbox.
10. Remove the oil/coolant heat exchanger (4).
11. Remove the stabilizer.
12. Disconnect the coolant hoses from the cylinder head and coolant pump housing by first loosening and folding back the clamps.
13. Disconnect the positive cable (X4) from its connection point to the bottom of the car and place it on the engine.
14. Unscrew the speed sensor.
15. Disconnect the plug of the oil level sensor (22).
16. Loosen the bottom bolts at the back (14) engine mounts.
17. Remove the bottom bolts from the front (12) engine mounts.
18. Automatic transmission: unscrew the holder of the transmission oil line (11/13) from the gearbox cover.
19. Hook the engine at the front and rear eyelets.
20. Unscrew the fastening bolts (6/6a) oil pan. If necessary, unscrew the holder (10) oil level sensor wiring (543), as well as the wire "masses" (w11/1) from the gearbox cover (with automatic transmission: transmission cable set (15/16)).
21. Raise the engine as horizontally as possible.
22. Remove the oil pan (8) in the direction of travel from the bottom to the front. Turn the crankshaft slightly if necessary. With automatic transmission, move the transmission oil lines slightly to the side. Make sure that the adjusting sleeve does not fall out (17).
23. Thoroughly clean the sealing surfaces of the oil pan and crankcase.
Installation
1. Check if there is an adjusting sleeve in the motor block (17).
2. Fix with a sealant, such as Omnifit-FD, a new gasket (9) in the engine block.
3. Install the oil pan, orienting it relative to the bearing surface of the gearbox, and tighten the bolts evenly by hand. Then alternately tighten the bolts with the following torques:
- 1. Bolt M 8 x 40 - 25 Nm.
- 2. Bolt M 6 x 35 - 10 Nm.
- 3. Bolt M 6 x 85 - 10 Nm.
- 4. Bolt M 6 x 20 - 10 Nm.
- 5. Bolt M 10 x 40 - 40 Nm.
- 4a. Bolt M 6 x 20 (with internal hexagon) - 10 Nm.
- 4b. Bolt M 6 x 75 (with internal hexagon) - 10 Nm.
- 4a and 4b - only with automatic transmission
Attention! If the oil pan is not oriented in the direction of the gearbox, this can lead to noise later on.
3. Lower the engine.
4. Plug in the oil level sensor plug.
5. Screw on the speed sensor.
6. Connect the positive wire to the underside of the car on the left.
7. Fit the coolant hoses to the cylinder head and coolant pump housing and secure with clamps.
8. Install stabilizer.
9. Install the oil/coolant heat exchanger.
10. Screw the front exhaust pipe to the manifold, to the exhaust pipe holder bracket on the gearbox.
11. Install the bottom cover of the engine compartment.
12. Install fan shroud, adjust and secure with clips.
13. Put on the air hose and secure with a screw clamp.
14. Fill with engine oil.
15. Fill with coolant.
16. Join "mass" batteries (–).
17. Set the clock.
18. Set the radio's anti-theft code.
19.Start the engine and check the oil pan for leaks.