Note: Remove the engine without the gearbox in an upward direction. During installation, all cable ties should be placed in their original locations. To be able to rotate the driveshaft on a four-wheel drive vehicle for removal, the power must be turned off before disconnecting the battery. mechanical parking brake. Risk of damage to electronic components when disconnecting the battery terminals. Follow the instructions when disconnecting the battery terminals. Remove the front wheels: right and left. Open the expansion lid. tank. Remove the sound insulation. Place a service tray under the engine. Screw drain cock "1" onto the fitting and drain the coolant, then remove fitting "2" from the radiator. Remove the front right and left fender liner.
Loosen clamp "1" and disconnect the air hose. Bring to service position. Remove the additional muffler.
Remove the "arrow" engine cover.
Disconnect hose "1" from the air filter. Release the air intake pipe "2". Remove the air filter housing. filter upwards with the "arrows" pointing upwards. Seal off the turbocharger using the plugs from the "VAS 6122" engine plug kit.
Remove the seal from the front wall of the water drainage box. Remove the cover of the water drainage box.
Remove the left and right elements "1" from the foam upwards in the direction of the "arrows".
Unlock the lock "arrow A" and open the cover "arrow B".
Loosen the nuts "1...3" of the wires. Remove the plug connection "4" from the holder and disconnect it. Unscrew screw "5" and remove the wiring splitter from the support.
Unlock the retainers on the wheel arch side using a 5.5 open-end wrench "pos. 1" and remove the pass-through insulator "2" upwards.
Open the cable channel by unlocking the lock "arrow B", pull the cable channel forward "arrow A" and release the wires.
Unscrew the nut "1" and tilt the filler neck of the washer fluid reservoir slightly forward "arrow A". Remove the filler neck "2" with the filler tube from the washer fluid reservoir, passing it through the body opening "arrow B".
Unscrew nuts "1" and remove holder "2". Unscrew nuts "3" and screws "4" and remove support "5".
Disconnect connector "1" from the boost pressure sensor "G31" and set it aside. Loosen clamp "2" and remove the air hose.
Remove coolant hose "2" and permanent exhaust "1".
Remove the permanent exhaust "1" and coolant hose "3" from the coolant expansion tank.
Disconnect hoses "1...3" by loosening the clamps.
Disconnect the "arrow" hoses.
Disconnect the "arrow" hoses.
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 the plug connectors "4" and unscrew the nut "3" securing the electrical wire. Disconnect (if available) plug connector "2". Unlock the "arrow" latches and remove the relay and fuse holders "1".
Unlock the clamps "arrow A" and remove the cable guide "1" in the upward direction "arrow B". Disconnect the engine wiring harness at the junction box in the engine. compartment and release it. Place the wiring harness on the engine and secure the engine control unit from falling out.
Disconnect connector "1" of the lambda probe "G39" and the lambda probe heater "Z19" and release the wiring. Disconnect connector "4" of the lambda probe after the "G130" neutralizer and the lambda probe heater 1 after the "Z29" neutralizer and release the wiring.
Unscrew nuts "1" from above.
Unscrew nuts "3" on the left and right and remove longitudinal rods "2".
Disconnect the hose clamp "arrow", remove the air duct hose and set it aside.
Unscrew nut "1" on the right side member and release the ground cables. Unscrew nut "2" of the bracket with electrical wiring on the right side of the car.
Disconnect the plug connection "1" of the radiator fan by moving the lock back "arrow" and pressing the stopper down. Place the wiring harness on the engine and secure it from falling.
Remove the vacuum pipe "2" from the end wall of the water drainage box; to do this, disconnect the vacuum hose "3" on the rear side of the "arrow".
Disconnect the "arrow" connector. Remove coolant hoses "1...4" and remove the end wall of the water drain box.
Unscrew screws "2...7".
Bolt "2" secures the starter to the gearbox and has an additional. spacer sleeve "arrow." When removing and installing the engine, remember to use the spacer sleeve "arrow." The spacer sleeve should be inserted between the starter and the transmission. Loosen clamp "2" and remove the air hose.
To reinstall the poly V-belt, mark the direction of rotation with chalk or a felt-tip pen before removing it. To loosen the poly V-belt, turn the tensioner in the direction of the arrow. Secure the tensioner with the T10060 A locking pin. Remove the poly V-belt.
Disconnect plug connection "1" of the electromagnetic clutch on the compressor. Unscrew the compressor "arrow" bolts.
Tie the compressor with the refrigerant hoses connected to the side member from above. Disconnect the fuel supply line. hose "1" by pressing the locking ring. Disconnect hose "2" from the activated carbon absorber.
Support the gearbox using a tilter and a mounted gearbox support.
Loosen the tunnel cross member arrow bolts.
Lower the KP using the tilting device to dimension "a". Dimension "a" = max. 80 mm.
Disconnect and release the plug connector "1" of the reversing light switch "F4" using the puller "T40138".
Unlock the electrical wire "A" from the gearbox and disconnect the electrical connector "C".
Disconnect threaded connection "1", unscrew bolt "2" and remove the catalytic converter mount.
Unscrew nut "2" from below and remove the neutralizer downwards. Raise the gearbox with a tilting device and screw in the tunnel crossmember arrow bolts.
Remove cover "1" from the bottom of the "arrow" gearbox.
Remove 3 bolts "arrow" of the driven disk. To do this, turn the crankshaft 120° in the direction of engine rotation.
Unscrew bolt "1" of the starter from the engine side. Remove the starter from the gearbox and leave it in the mounting position. Loosen the remaining "8...10" engine-to-gearbox mounting bolts. Install the "10-222 A" crossmember with the "10-222 A/8" adapter onto the left and right shock absorber cups, as shown in the figure. Connect the gearbox and lead screw to the mounting bracket "3147", For better presentation shown with the engine removed. Slightly pre-tension the spindles of the 10-222 A crosshead!
Hang the "2024 A" lifting device on the engine and the "VAS 6100" service crane as shown in the figure. The hooks and locking pins of the hanging device must be secured with pins.
Unscrew bolts "1" of the right and left engine mounts. Ignore the arrow. Raise the engine enough to clear the engine mounts. Tighten the lead screw of the 10-222 A crosshead.
Risk of damage to hose and wire connections, as well as motor. compartment. Make sure that all hose and wire connections between the engine, transmission, subframe, and body are disconnected. When removing the engine from the motorcycle. be careful when entering the compartment. Disconnect the engine from the gearbox and remove it upwards from the engine. compartment.
Engine installation
Tightening torques (Nm)
| Bolts and nuts | M6 | 9 |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 |
Fastening the engine to the manual transmission
| Pos. | Bolt | N m |
| 1(3) | M10 x 50 (1) | 65 |
| 2(3), 7 | M12 x 100 (2) | 30 + 90° |
| 3(4), 6 | M12 x 75 (2) | 30 + 90° |
| 4...5(4) | M12x120 (2) | 30 + 90° |
| 8...10 | M10 x 75 (2) | 15 + 90° |
| 11 | M12 x 50 (2) | 30 + 90° |
| A | Alignment bushings | |
(1) Steel bolt - do not replace.
(2) Replace the bolts.
(3) Additionally secures the starter.
(4) Additionally secures the cable mount.
Note: Replace bolts that have been over-tightened. Replace self-locking nuts, lip seals, gaskets and seals. rings. Hoses and hose fittings syst. air boosters must be cleaned of oils and grease before installation. Secure all hose connections with hose clamps of the appropriate series. During installation, all cable ties should be placed in their original locations. Check the presence of bushings in the cylinder block for centering the engine and gearbox; insert bushings if necessary. Be sure to clean the threaded holes for securing the power unit in the cylinder block with a tap before assembling the transmission. Before securing the engine to the transmission, do the following: Check that the intermediate shield is suspended on the flange and seated on the mounting bushings. To locate the inspection hole, rotate the clutch module.
The following action is necessary if the driven disk is installed with the locking pin "2". Align the additional. driven disk in relation to the clutch module so that the locking pins "2" (if available) on the driven disk entered the large holes "1" on the clutch module. If the locking pins of the driven disc "2" are not located in the holes of the clutch module "1", this can lead to significant problems with the operation of the clutch.
Bolt "2" secures the starter to the gearbox and has an additional. the "arrow" spacer sleeve. When removing and installing the engine, remember to use the "arrow" spacer sleeve. The spacer sleeve must be inserted between the starter and the transmission.
Install the gearbox onto the engine and tighten bolts "7...11" connecting the engine and gearbox. Release the lead screw of the "10-222 A" crossmember. Lower the service crane and place the engine and gearbox on the engine mounts.
Screw in bolts "1" of the right and left engine mounts. Remove the crane and suspension device.
Screw in and tighten bolts "1...6" for fastening the engine to the gearbox. "Pos. A" should not be taken into account. The next step is necessary to ensure that the clutch module fits evenly against the driven disc and does not become warped. Lightly press the clutch module "2" using the mounting lever "1" to the driven disc of the clutch "3" in the direction of the "arrow".
Tightening sequence - clutch module to driven disc
Tighten the first "arrow" bolt by hand. Turn the crankshaft 120° in the direction of engine rotation and tighten the second bolt by hand. Turn the crankshaft another 120° in the direction of engine rotation.
Now tighten the 3rd bolt to the specified tightening torque. Now tighten the remaining bolts to the specified torque. Installation in reverse order. Install the starter. Install the catalytic converter. Install add. muffler. Install the exhaust system without stress. Install the compressor. Install the poly V-belt. Install the engine control unit. Install the wires, the 2-way splitter 30 "TV22" and the cover of the motorcycle switching unit. compartment. Install the stretcher. Install the washer reservoir filler neck. Follow the instructions after connecting the battery terminals. Install the air conditioner housing. filter. Return to the service position. Check the oil level. Fill with coolant. Install noise insulation screens and fender liners.