Note: The engine is removed upwards without the gearbox. When reassembling, reinstall all cable ties in their original locations. Follow the instructions when disconnecting the battery terminals.
Disconnect ground wire "2" from the battery terminal.
Remove the "arrow" engine cover.
Open the expansion lid. tank. Remove the front right and front left fender liner.
Remove noise insulation screens "1" and "2".
Place a service tray under the engine. Screw drain cock "1" to the fitting and drain the coolant, then remove fitting "2" from the radiator by lifting the mounting bracket. Release the coolant hose on the side member.
Remove the air duct hose and push it to the side; to do this, loosen the "arrow" clamp.
Unscrew the exhaust pipe "arrow" nuts.
Do not bend the connecting elements of the front exhaust pipe more than 10°. Unscrew the threaded connections "arrows", slide the clamping sleeve back and remove the exhaust pipe.
Unscrew bolt "2" of the diesel particulate filter suspension. "Pos. 1" should not be taken into account.
If present, disconnect the "arrow" plug connection on the steering gear.
Bring the lock mounting beam into service. position. Unscrew bolts "1" and remove the front engine mount. Unscrew the bolts on the left and right "2" and remove the cross member "3".
Remove cover "1" from the bottom of the "arrow" gearbox.
Remove the cap from the vibration damper. To loosen the driven disk bolts, use the bent open-end wrench "1" to hold the central bolt on the vibration damper. During the final turn, rotate the crankshaft only in the direction of engine rotation "arrow".
Unscrew the 3 bolts "arrow" of the driven disk, to do this, turn the crankshaft in 120° increments in the direction of engine rotation.
Unscrew the bolts "1, 7, 8, 9, 10" engine and gearbox connections. "Pos. A" should not be taken into account. Turn the tensioner element clockwise "arrow", remove the compressor V-belt from the pulley and lock the tensioner element with the retainer "T40098". Remove the poly V-belt.
Disconnect plug connections "1" and "2" and release the electrical wires. Unscrew the compressor "arrow" bolts. Tie the compressor with the connected lines to the side. "Pos. 3" should not be taken into account.
Remove the plug connection "1" of the radiator fan from the mount by moving the lock back "arrow" and pressing the stopper down. Release the radiator fan control unit wire harness.
Unscrew the "arrow" nut on the right side member and release the ground wires.
Remove the coolant hoses by loosening the fastening clamps "1" and "3". Ignore "Pos. 2" and the "arrows".
Remove the air duct hose by loosening the hose clamps "arrows". Disconnect the plug connection of the charge pressure sensor "G31" / intake manifold air temperature sensor "G42" "pos. 1" and release the wiring.
Disconnect plug connection "3" of the air flow meter "G70". Remove the air duct hose from the air flow meter "G70" by loosening the hose clamp "4". Disconnect the vacuum hose "arrow". Remove the air flow meter housing. filter "2" and, if present, disconnect the plug connection "1" on its reverse side from the air bypass damper valve. filter "N275".
For reinstallation, mark the position of the poly V-belt pulley of the vane pump in relation to the hub "arrow".
Unscrew the "arrow" bolts, using a 2-hole "3212" wrench as a support, and remove the poly V-belt pulley of the impeller pump.
Unscrew the "arrow" bolts and tie up the vane pump with the connected hydraulics. highways to the side.
Remove the coolant hose by loosening the fastening clamp "2". Ignore "Pos. 1".
Remove the fuel hoses by loosening the hose clamps.
1. Fuel hose is yellow. 2. Fuel hose is blue. 3. The fuel hose is white.
Remove the foam elements "1" from the left and right in an upward direction.
Remove the cover of the water drainage box "1".
Unlock the lock "arrow A" and open the cover "arrow B".
Loosen the nuts on wires "1...3." Remove plug connection "4" from its holder and disconnect it. Unscrew bolt "5" and remove branch pipe 2 cl. 30 "TV22" from the front wall of the "arrow" water drainage box.
Disconnect the plug connection from the brake booster pressure sensor "G294" "arrow".
Unlock the retainers from the wheel arch using a 5.5 open-end wrench "pos. 1" and remove the cable entry "2" upwards. Release the wire bundle "3" to the generator and starter using the release lever "80-200".
Open cable channel "1" by unlocking the "arrow" latch and releasing the bundle of wires.
Remove the vacuum pipe "1" from the end wall of the water drainage box; to do this, disconnect the vacuum hose "2" on the rear side of the "arrow".
Unscrew the nut "1" and tilt the filler neck of the washer fluid reservoir slightly upwards "arrow A". Remove the filler neck "2" with the filler tube from the washer fluid reservoir, passing it through the body opening "arrow B".
On a vehicle with an independent heater, unscrew bolts "2" and put aside pump block "1".
Unscrew the arrow bolts and remove the cover of the motorcycle switching unit. compartment. Unscrew nut "1" and release the wire.
Unlock the "arrow A" fasteners and remove the "arrow B" engine control unit.
Disconnect (if available) plug connection "2". Disconnect plug connections "4" and unscrew wire fastening nut "3". Unlock the "arrow" latches and remove the relay and fuse "1" holders. Remove and free the engine wire harness secured in the switch. engine compartment block.
Unlock the retainers "arrows A" and remove the cable guide "2" upwards "arrow B". Release the wiring harness, place it on the engine and secure the engine control unit against falling. "Pos. 1" should not be taken into account.
Cars without independent heating: Unscrew nut "5". Remove the coolant hoses by loosening fastening clamps "1, 2". Route the coolant hoses through the front wall of the water drain box and release them. "Pos. 3, 4" do not take into account.
Cars with independent heating: Unscrew nut "3". Remove the coolant hoses by loosening hose clamps "1, 2". Route the coolant hoses through the front wall of the water drain box and release them.
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Remove the front wall of the water drainage box. Disconnect plug connection "3" of differential pressure sensor "G505". Unscrew bolt "2" and release hoses "1" from the holder. Place the differential pressure sensor "G505" back.
Release the "arrow" wire harness. Unscrew nuts "1" and remove holder "2". Remove the lambda probe.
Remove the plug connector from the bracket and disconnect it:
4. For exhaust gas temperature sensor 3 "G495". "Pos. 1, 2" do not take into account.
Unscrew the "arrow" nuts and put the particulate filter back.
Disconnect plug connection "2" from the reversing light switch "F4" and release the wire. "Pos. 1, 3" do not take into account.
Unclip electrical wire "A" from the gearbox and disconnect plug connection "C". Ignore "Pos. B".
Disconnect the "arrow" plug connection from the gearbox neutral sensor -G701 - and release the wire.
Unscrew bolts "2...6" connecting the gearbox and the engine. Remove the starter from the gearbox and leave it in the mounting position. position. "Pos. A" should not be taken into account. Bolt "2" secures the starter to the gearbox and has an additional. spacer sleeve "arrow".
Install the "10-222 A" crossmember on the shock absorber strut cups on the left and right, as shown in the figure. Attach the "10-222 A/12" earrings to the gearbox and thread the "10-222 A/11" lead screw through. For a better understanding of the installation. the position is shown with the engine removed. Slightly tighten the gearbox using the lead screw of the traverse "10-222 A/11".
Remove the eye of the "2024 A" suspension device by disconnecting the pin and pressing in the bolt. Reinstall the eyelet into the 4th hole on the front of the hanging fixture. Secure the bolt with a stud. Attach the "2024 A" suspension device to the engine and the "VAS 6100" service crane as shown in the figure.
Unscrew the bolts "1" of the engine mount on the left and right. Unscrew nut "2" and release the holder with electrical wires. Remove the left and right "arrow" plug connections from the holder and disconnect them. Raise the engine enough to clear the engine mounts. Tighten the lead screw "10-222 A/11". Ensure that all hose and wire connections between the engine, gearbox, subframe, and body are disconnected. When removing the engine from the motorcycle. be careful when entering the compartment.
While removing engine 2, the mechanic must carefully open the hood, ensuring the maximum opening angle. To do this, lightly pry up the retaining spring "arrow" on the left and right with a small screwdriver and remove the gas-filled shock absorber "1" from the top of the ball joints "2". Disconnect the engine from the gearbox and lift it upwards from the engine. compartment. Press the gas-filled shock absorbers back into the ball joints.
