Withdrawal
1. Place the shift lever in neutral position.
2. Remove the seal from the fairing (see arrows in illustration), and then remove the fairing grille 1.
8.2. Remove seal from fairing (see arrows), and then remove the fairing grille
Attention! If the radio has an access code, then when the battery is disconnected, it is erased, so check and write down this code. Otherwise, the radio can only be turned on with the assistance of a manufacturer's representative.
3. Disconnect the wire terminal «masses» (-) from the negative pole of the battery by unscrewing the nut (see arrow in illustration).
8.3. Disconnect wire terminal «masses» (-) from the negative pole of the battery by unscrewing the nut (see arrow)
Attention! The manufacturer recommends draining the refrigerant from the air conditioner. However, you must not open the refrigerant circuit yourself - risk of frostbite! You can try to disconnect the air conditioning compressor without opening the system and without disconnecting hoses and pipes from it, and move it away from the place of work.
4. Remove the cap from the coolant expansion tank.
Attention! Before removing the cap from the expansion tank, place a rag on it to prevent burns from hot coolant or steam.
5. Remove the front wheels.
6. Vehicles with parking heater. Unscrew the bolts (see arrows in illustration) fixing the heater pipe to the soundproof shield.
8.6. Unscrew the bolts (see arrows) fixing the heater pipe to the soundproof shield. Vehicles with parking heater
7. Unscrew the bolts / remove the clamps 1-3 and remove the engine mudguard (see illustration).
8.7. Unscrew the bolts/remove the clips 1-3 and remove the engine mudguard
8. Remove the bolts (see arrows in illustration) engine mudguard bracket and remove the bracket.
8.8. Unscrew the bolts (see arrows) engine mudguard bracket and remove the bracket
9. Remove the front bumper (see relevant chapter).
10. Disconnect the plug (see arrow in illustration) sound signal.
8.10. Disconnect the plug (see arrow) sound signal
11. Remove the left fairing (see arrow in illustration 8.11) and right fairing (see arrow in illustration 8.11a) additional radiator.
8.11. Remove the left fairing (see arrow) additional radiator | 8.11a. Remove the right fairing (see arrow) additional radiator |
12. Install a suitable container under the engine to collect the coolant.
13. Unscrew the plug (see arrow in illustration) drain hole on the thermostat housing and drain the coolant.
8.13. Unscrew the stopper (see arrow) drain hole on the thermostat housing and drain the coolant
14. Disconnect the lower hose from the radiator (see arrow in illustration) and drain the coolant from the radiator.
8.14. Disconnect the lower hose from the radiator (see arrow) and drain the coolant from the radiator
15. Place a suitable container to collect the transmission oil and disconnect the transmission oil circulation hose from the radiator frame (see arrow in illustration).
8.15. Disconnect the transmission oil circulation hose from the radiator frame (see arrow)
16. Disconnect the hose from the transmission oil cooler (see arrow in illustration).
17. Remove the cap from the expansion tank of the power steering (see arrow in illustration).
8.17. Remove the cap from the expansion tank of the power steering (see arrow)
18. Wring out the clamps and remove the cover 2 of the air filter (see illustration).
8.18. Squeeze the latches and remove the cover 2 of the air filter
19. Remove the bolts (see arrows in illustration 8.18) fastening the air intake 1 to the upper cross member of the front end and remove the air intake.
20. Disconnect the headlight power plugs on both sides (see arrow in illustration).
8.20. Disconnect the headlight power plugs on both sides (see arrow)
21. Release plugs 1 and 2 from the holders and move the wiring harness away from the work area (see illustration).
8.21. Release plugs 1 and 2 from the holders and move the wiring harness away from the work area
22. Disconnect the plug (see arrow in illustration) radiator fan, release the wiring harness from the holder.
8.22. Disconnect the plug (see arrow) radiator fan
23. Remove the hood drive cable.
24. Disconnect the upper hose from the radiator (see arrow in illustration).
8.24. Disconnect the top hose from the radiator (see arrow)
25. Remove the bolts (see arrows in illustration), release the clips and remove the left and right radiator fairings.
8.25. Unscrew the bolts (see arrows), wring out the latches and remove the left and right radiator fairings
26. Disconnect the sensor 1 outdoor temperature and release the wire from the holder (see illustration).
8.26. Disconnect the outdoor temperature sensor 1 and release the wire from the holder
27. Remove the bolts (see arrows in illustration 8.26) power steering line holders and move the line away from the work site without opening the system. Carefully tie up the piping to avoid damaging it.
28. Unscrew the bolts of the holders (see arrows in illustration) and disconnect the refrigerant lines from the A/C compressor.
8.28. Unscrew the screws of the holders (see arrows) and disconnect the refrigerant lines from the A/C compressor
Attention! All work related to the air conditioner should be entrusted to a specialized workshop. Do not open the refrigerant circuit yourself - risk of frostbite.
29. Remove the bolts (see arrows in illustration) on the right and left sides of the upper cross member of the front end.
8.29. Unscrew the bolts (see arrows) on the right and left sides of the upper cross member of the front
30. Unscrew the bolts of the shock absorbers (see arrows in illustration) and carefully remove the radiator frame, working together with an assistant.
8.30. Remove the shock absorber bolts (see arrows) and carefully remove the radiator frame, working together with an assistant
31. Remove engine protection covers (see arrows in illustration).
8.31. Remove engine protection covers (see arrows)
32. Disconnect the coolant hoses from the expansion tank 2 by removing the clamps 1 and 3 (see illustration).
8.32. Disconnect the coolant hoses from the expansion tank 2 by removing the clamps 1 and 3
33. Unscrew the mounting bolts (see arrows in illustration 8.32) and remove the coolant expansion tank 2.
34. Disconnect low pressure hoses (see arrows in illustration).
8.34. Disconnect low pressure hoses (see arrows)
35. Disconnect the coolant hose by removing the clamp (see arrow in illustration).
8.35. Disconnect the coolant hose by removing the clamp (see arrow)
36. Disconnect the low pressure hose from the intake manifold (see arrow in illustration).
8.36. Disconnect the low pressure hose from the intake manifold (see arrow)
37. Disconnect the coolant hose from the engine (see arrow in illustration).
8.37. Disconnect the coolant hose from the engine (see arrow)
38. Disconnect the plug (see arrow in illustration) from the vacuum brake booster and release the wire from the holder.
8.38. Disconnect the plug (see arrow) from the vacuum brake booster
39. Pump out the fluid from the power steering reservoir using an oil pumping tool, catalog number VAG 1358A or VAG 1782A. Collect the escaping liquid with a rag.
40. Disconnect the hose from the power steering reservoir by removing the clamp 1 (see illustration).
8.40. Disconnect the hose from the power steering reservoir by removing the clamp 1
41. Disconnect the coolant hoses by removing the clamps (see arrows in illustration).
8.41. Disconnect the coolant hoses by removing the clamps (see arrows)
42. Disconnect the coolant hose (see arrow in illustration) from the oil cooler.
8.42. Disconnect the coolant hose (see arrow) from oil cooler
43. Disconnect the coolant hoses by removing the fastening clamps (see arrows in illustration).
S.43. Disconnect the coolant hoses by removing the clamps (see arrows)
44. Cars with an afterburning system. Disconnect plug 1 from the fresh air pump motor to the exhaust valves and release the wire from the holder (see illustration).
8.44. Disconnect plug 1 from the fresh air pump motor to the exhaust valves and release the wire from the holder. Vehicles with an afterburning system
45. Disconnect wire 2 «masses» (-) from the spar (see illustration 8.44).
46. Disconnect plugs 1 and 2 located in front of the air filter (see illustration).
8.46. Disconnect plugs 1 and 2 located in front of the air filter
47. Release the plug 3 of the solenoid valve of the adsorber from the holder 2 (see illustration), then remove the valve.
8.47. Release the plug 3 of the canister solenoid valve from the holder 2
48. Disconnect plug 4 mass air flow sensor (see illustration 8.47).
49. Disconnect the hose 1 of the fresh air pump to the exhaust valves (see illustration 8.47).
50. Remove clamp 5 fastening and disconnect the supply air duct from the air filter housing (see illustration 8.47).
51. Remove the bolt (see arrow in illustration 8.47) fasteners and remove the air filter housing together with the mass air flow sensor.
52. Remove the clamp (see arrow in illustration) fasteners and disconnect the supply air duct from the throttle valve.
8.52. Remove clamp (see arrow) fasteners, disconnect the supply air duct from the throttle valve
53. Disconnect supply 1 and return 2 fuel lines (see illustration).
8.53. Disconnect supply 1 and return 2 fuel lines
Attention! The fuel system is under pressure. Before disconnecting the fuel lines, cover the joint with a rag. Disconnect the fuel line slowly to depressurize the system.
54. Cars with an afterburning system. Remove the fastening clamp (see arrow in illustration) and disconnect the hose from the fresh air valve to the exhaust valves.
8.54. Remove the fastening clamp (see arrow) and disconnect the hose from the fresh air valve to the exhaust valves
55. Disconnect the plugs 1-4 located on the bulkhead of the engine compartment (see illustration) and move the wiring harness away from the work area.
8.55. Disconnect plugs 1-4 located on the bulkhead of the engine compartment
56. Disconnect the positive potential wire terminal (+) from the battery by unscrewing nuts 1 and 2 (see illustration).
8.56. Disconnect the positive potential wire terminal (+) from the battery by unscrewing nuts 1 and 2
57. Disconnect plug 3 of the brake booster vacuum sensor (see illustration 8.56) and release the sensor wire from the holder.
58. Remove the bolts (see arrows in illustration) and remove the engine control unit cover.
8.58. Unscrew the bolts (see arrows) and remove the cover of the engine control unit
59. Pry off the mounting bracket with a screwdriver (see arrow in illustration) and remove the engine control unit without disconnecting the wiring harness from it.
8.59. Pry off the bracket with a screwdriver (see arrow) and remove the engine control unit without disconnecting the wiring harness from it
60. Disconnect plugs (see arrows in illustration) engine control unit.
8.60. Disconnect plugs (see arrows) engine control unit
61. Pry the retainer with a screwdriver (see arrow in illustration) and remove the fuse and relay box.
8.61. Pry off the retainer with a screwdriver (see arrow) and remove the fuse and relay box
62. Disconnect the wiring harness from the engine control unit.
63. Disconnect the wire «masses» (-), by unscrewing the nut 2 (see illustration).
8.63. Disconnect the wire «masses» (-), by unscrewing the nut 2
64. Release the wiring harness from the holder, then unscrew the bolts 1 and remove the holder (see illustration 8.63).
65. Unscrew the bolts 1 and 2 of the holders and disconnect the pipes of the exhaust system (see illustration).
8.65. Unscrew the bolts 1 and 2 of the holders and disconnect the pipes of the exhaust system
66. Remove the bolts (see arrows in illustration) and remove both heat shields.
8.66. Unscrew the bolts (see arrows) and remove both heat shields
67. Remove the bolts (see arrows in illustration) and remove the heat shield A of the cardan shaft.
8.67. Unscrew the bolts (see arrows) and remove the heat shield A of the cardan shaft
68. Loosen the fastening bolts and carefully slide the propeller shaft to the gearbox flange. Tie the shaft with wire to the body.
69. Remove the bolts (see arrows in illustration) and remove the transmission heat shield.
8.69. Unscrew the bolts (see arrows) and remove the transmission heat shield
70. Remove the bolt (see arrow in illustration) fixing the lining of the left exhaust pipe.
8.70. Screw out 6olt (see arrow) fastenings of an overlay of the left reception pipe
71. Unscrew bolts 1,3 and 4 and remove the heat-reflecting shield together with the bracket for the exhaust system (see illustration).
8.71. Unscrew bolts 1, 3 and 4 and remove the heat deflector together with the bracket for the exhaust system
72. Unscrew the bolt 2 of the holder of the tip of the gear selection cable (see illustration 8.71).
73. Disconnect the ball joint of the tip of the gear selection cable (see arrow in illustration 8.71) from the shift rod lever on the gearbox.
74. Unscrew the bolts 1 and 2 fastening the left and right gearbox suspension mounts (see illustration).
8.74. Unscrew bolts 1 and 2 of fastening of the left and right support of a suspension bracket of a transmission
75. Turn the latch 1 and disconnect the plug of the transmission wiring harness (see illustration).
8.75. Turn the lock 1 and disconnect the plug of the transmission wiring harness
76. Disconnect the plug 2 of the multifunction switch of the gearbox, remove the holder 3 of the plug (see illustration 8.75).
77. Remove the heat-reflecting shields 1 of both drive shafts (see illustration).
8.77. Remove the heat-reflecting shields 1 of both drive shafts
78. Disconnect both drive shafts from the gearbox, then shift and tie up the right drive shaft and remove the left drive shaft (see relevant chapter).
8.78. Unscrew bolts 1 and 2 and disconnect the refrigerant circulation pipes from the air conditioning compressor
79. Unscrew bolts 1 and 2 and disconnect the refrigerant circulation pipes from the air conditioning compressor (see illustration).
Attention! All work related to the air conditioner must be entrusted to a specialized workshop. Do not open the refrigerant circuit yourself - risk of frostbite!
80. Remove the collar (see arrow in illustration) fixing the refrigerant piping.
8.80. Remove clamp (see arrow) refrigerant piping fasteners
81. Remove the bolt (see arrow in illustration) fasteners and remove the refrigerant piping.
8.81. unscrew the bolt (see arrow) fasteners and remove the refrigerant circulating pipe
82. Disconnect the power steering pressure hose by unscrewing the union nut (see arrow in illustration). Collect the escaping liquid with a rag.
8.82. Disconnect the power steering pressure pipe by unscrewing the union nut (see arrow)
83. Disconnect the discharge pipe from the power steering pump (see arrow in illustration).
8.83. Disconnect the pressure line from the power steering pump (see arrow)
84. Unscrew the nuts 1-4 of the mounting pads of the anti-roll bar (see illustration).
8.84. Unscrew the nuts 1-4 of the anti-roll bar mounting pads
85. Cars with automatic transmission. unscrew the bolt (see arrow in illustration) transmission oil circulation pipe holder and disconnect the pipes. Collect the leaking oil with a rag.
8.85. unscrew the bolt (see arrow in illustration) transmission oil circulation pipe holder and disconnect the pipes. Cars with automatic transmission
86. Cars with automatic transmission. Disconnect the pipeline from the transmission oil cooler (see arrow in illustration).
8.86. Disconnect the pipeline from the transmission oil cooler (see arrow). Cars with automatic transmission
87. Cars with automatic transmission. Unscrew the bolts 1 and 2 of the transmission oil circulation pipe bracket, remove the bracket, and then carefully remove the pipes (see illustration).
8.87. Unscrew the bolts 1 and 2 of the bracket for fastening the transmission oil circulation pipes, remove the bracket, and then carefully remove the pipes. Cars with automatic transmission
88. Unscrew the bottom nuts 1 of the right and left engine mounts (see illustration), loosen the upper left engine mount nut.
8.88. Unscrew the lower nuts 1 of the right and left engine mounts
89. Unload the supports of the power unit, for which lift the engine and gearbox using a hoist or hoist. In specialized workshops, a service crane VAS 6100 and jack 1 are used for this, which is installed under the gearbox (see illustration).
8.89. Unload the power block supports by lifting the engine and gearbox with a service crane VAS 6100. Jack 1 is placed under the gearbox
Attention! Do not place a stand or jack under the oil pan.
90. Unscrew first the lower and then the upper bolts securing the gearbox to the engine.
91. Cars with automatic transmission. Disconnect the torque converter from the drive plate to which it is attached with three bolts. The bolts are unscrewed alternately through the mounting hole for the starter (see illustration), so the starter must first be removed (see relevant chapter). In order for the bolts to go into the starter mounting hole, turn the engine with the socket head for the bolt on the crankshaft to the right.
8.91. Unscrew the bolts securing the starter to the drive disk, one by one leading the bolts into the hole for the starter (see arrow). Cars with automatic transmission
92. Carefully separate the engine and transmission, preventing the torque converter from falling out. Then remove the engine from the engine compartment.
Installation
The engine is installed in the reverse order of removal.
93. Tighten the bolts securing the gearbox to the engine in the sequence shown in the illustration:
- 1 - bolt M10x80. Tightening torque - 65 Nm (if bolt without ribbed head), 85 Nm (if the ribbed bolt);
- 2, 4, 5 - M12x105 bolt. Tightening torque - 65 Nm;
- 3 - bolt M12x110. Tightening torque - 65 Nm;
- 6 - bolt M12x120. Tightening torque - 65 Nm;
- 7 - bolt M12x170. Tightening torque - 65 Nm;
- 8-10 - M10x60 bolt. Tightening torque - 45 Nm.
8.93. Tighten the bolts securing the gearbox to the engine in the following sequence: A - centering bushings
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