Remove
- 1. Open bonnet
- 2. Disconnect battery • Detach ground clamp from ground terminal – Unscrew nut
- 3. Disconnect vacuum line of vacuum pump at brake servo • Release clamp (1) • 3x unclip bracket
- 4. Remove oil dipstick (1)
- 5. Detach oil dipstick guide tube from bracket (2) • Release clamp
- 6. Raise vehicle all the way
- 7. Remove right engine splash guard • Unscrew 3 bolts (1) • Remove body-bound rivet (arrow)
- 8. Remove ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow • Use KM-913-A
Note. Mark running direction.
- 9. Disconnect wiring harness plug (1) of engine oil level sensor
- 10. Place collecting basin underneath.
- 11. Drain engine oil • Unscrew oil drain bolt (1) • Replace gasket • Tighten oil drain bolt 78.4 Nm
- 12. Remove alternator • Remove solenoid valve vacuum line (6) • Detach electrical connection (2) – Unscrew nut • Disconnect wiring harness plug (1) • Detach brake servo vacuum line (3) – Unscrew union nut • Detach vacuum pump oil feed line (5) – Unscrew banjo bolt • Detach vacuum pump oil return line (4) – Release clamp • Unscrew 2 bolts (7)
- 13. Remove vacuum pump oil return hose (1) • Unclip bracket • Release clamp
- 14. Detach front exhaust pipe from catalytic converter • Unscrew 3x nut (1)
- 15. Detach exhaust system • Detach 2 rubber mountings (1)
Note. Attach to underbody with suitable material
- 16. Remove heat shield of primary catalytic converter • Unscrew 3 bolts (1)
- 17. Remove primary catalytic converter • Detach from turbocharger – Unscrew 4x bolt (1) • Detach from bracket – Unscrew 2 bolts (2)
Note. Note dissimilar bolt lengths
- 18. Remove oil dipstick guide tube • Unscrew 2 bolts (1)
Install
- 19. Install oil dipstick guide tube • Replace gasket • Tighten 2 bolts 9.8 Nm
- 20. Clean sealing surfaces
- 21. Install primary catalytic converter • Attach to turbocharger using new gasket – Tighten 4 bolts • Attach to bracket – Tighten 2 bolts
Note. Note dissimilar bolt lengths
- 22. Install heat shield of primary catalytic converter • Tighten 3 bolts 11.8 Nm
- 23. Attach exhaust system • Attach 2 rubber mountings
- 24. Attach front exhaust pipe to catalytic converter • Replace gasket • Tighten 3 new nuts 25 Nm
- 25. Install vacuum pump oil return hose • Fasten clamp • Clip in bracket
- 26. Install alternator • Tighten 2 bolts – Tightening torque (M8) 18.6 Nm – Tightening torque (M10) 46.1 Nm • Attach vacuum pump oil return line – Fasten clamp • Attach vacuum pump oil feed line – Replace 2 gaskets – Tighten banjo bolt • Attach brake servo vacuum line – Tighten union nut • Connect wiring harness plug • Attach electrical connection – Tighten nuts • Attach solenoid valve vacuum line
- 27. Install ribbed V-belt • Tension ribbed V-belt tensioner in direction of arrow using KM-913 via bolt (1) and position ribbed V-belt – I. Ribbed V-belt without AC – II. Ribbed V-belt with AC
Note. Note ribbed V-belt's direction of travel
- 28. Install right engine splash guard • Tighten 3 bolts • Install body-bound rivet
- 29. Lower vehicle all the way
- 30. Attach oil dipstick guide tube to bracket • Fasten clamp
- 31. Insert oil dipstick.
- 32. Connect vacuum line of vacuum pump to brake servo • Fasten clamp • 3x clip in bracket
- 33. Connect battery • Attach ground clamp to ground terminal – Tighten nuts
- 34. Program volatile memory
- 35. Close bonnet