Remove trunk tray -3-. If present, remove Bassbox -2-. Unscrew the floor covering -1- above the cover.
Unlock fastenings -arrows- and install cover -1-.
Open the cover -1- over the negative terminal of the battery. Unscrew the nut a few turns and remove the pole piece -arrow- of the ground cable from the battery terminal.
Remove engine cover -arrows-. When the engine is warm, the cooling system is under excess pressure. To relieve excess pressure, cover the expansion cap. coolant reservoir with a rag and carefully open it. Open the extension cover. tank. Remove the front wheels: right and left. Remove the front right and left fender liner.
Remove noise insulation panels -1- and -2-
Place service tap tray -VAS 6208- under the engine. Screw the drain valve -1 - onto the fitting and drain the coolant, then remove the fitting -2- from the radiator, to do this lift the clamping bracket.
Release hose clamp -arrow-, remove air inlet hose and lay to one side.
Unscrew the nut -arrow- on the right side member and release the ground cables.
Unscrew the nuts -arrows- of the exhaust pipe.
Unscrew the screw connections -arrows-, push the clamping sleeve back and remove the exhaust pipe.
Unscrew screw connection -1-.
-Pos. 2- do not take into account.
Disconnect connector -arrow- from steering gear.
Remove the cover -1 - from the bottom of the gearbox -arrow-.
Remove the cover from the vibration damper. Unscrew the 3 bolts -arrow-of the driven disc; to do this, rotate the crankshaft through 120°in the direction of engine rotation.
Unscrew bolts -1,7,8, 9,10- connecting the engine and gearbox. -Pos. A - ignore. There is a risk of damage to a previously used poly V-belt when its travel is changed. For reinstallation, before removing the poly V-belt, mark the direction of its movement with chalk or a felt-tip pen. Turn the tensioning element -in the direction of the arrow-, remove the poly V-belt from the air conditioning compressor pulley and secure the tensioning element with the clamp -T40098-. Remove the poly V-belt.
Disconnect and release plug connectors -1- and -2-. Remove bolts -arrows- for air conditioning compressor. Do not overtighten, bend or bend refrigerant lines and hoses. Tie the compressor with the connected lines to the side. -Pos. 3- ignore.
Remove the electrical connector -1 - of the radiator fan from the bracket; to do this, push the lock back -arrow- and press the lock down. Release email cables to the radiator fan control unit.
Unscrew bolt -arrow- and move radiator fan control unit -1- to one side. -Pos. 2.3 - do not take into account.
Unscrew the bolts -arrows- while holding the central bolt. Remove the vibration damper.
Unscrew bolt -arrow- and remove intermediate roller.
Unscrew bolts -arrows- and move bracket -1- to rear. In the picture there is a mot. The compartment is shown from below towards the turbocharger.
Remove the coolant hoses by unclamping the retaining clips -1- and -3-. -Pos. 2- and -arrows- are ignored.
Loosen the hose clamps -arrows- and remove the air inlet hose. Disconnect the plug connector of the boost pressure sensor - pos. 1- and release the connector.
Unscrew bolt -1-. -Pos. 2, 3 - do not take into account.
Unscrew the nut -3- and disconnect the plug connector -1-. Remove exhaust gas recirculation radiator pump -V51- -item. 2- with bracket and set aside with coolant hoses connected.
Unscrew the double bolt -2- and pull the coolant pipe -1- with the connected coolant hoses -in the direction of the arrow-.
Unscrew terminal 30/V+ -pos. 1-. Disconnect el. connector -2-.
Unscrew bolts -arrows-. If the generator jams in the bracket, tighten the mounting bolts again up to 2 turns. Gently tap the bolt head with the flat end of a hammer to loosen the generator mounting bushings. Remove the generator -1 - by pulling the coolant pipe to the side.
Unscrew the bolts -arrows- and remove the serpentine belt pulley for the general power steering pump.
Unscrew the bolts -arrows- and secure the pump with the connected hydraulic lines to the side at the top.
Remove the coolant hose by unclamping the retaining clip -2-. -Pos. 1 - do not take into account.
Unscrew bolt -1- and remove tensioner -2- from poly V-belt -arrow-.
Release the brackets -arrows- and remove the toothed belt protective cover.
Remove air duct -arrow-.
Disconnect plug connector -3- for air mass meter -G70-. Remove the air hose from the air mass meter -G70- by unclamping the clamp -4-. Disconnect vacuum hose -arrow-. Remove the air housing. filter -2-, disconnect on the reverse side (in the presence of) Connector -1- for air intake switching valve -N335-.
Disconnect fuel supply -1- and return -2- lines.
Unscrew bolts -1- and nuts -2-, remove the extension.
Remove the foam elements -1- and -2- on the left and right, upwards.
Remove seal -3-. Release the mounting clips -1- from the mountings and remove the plenum chamber cover -2-.
Unlock lock -arrow A- and open cover -arrow B-.
Unscrew the nuts -1...3- el. wires Remove email plug connection -4- from the holder and disconnect it. Unscrew bolt -5- and remove splitter 2 cells. 30 -TV22- from the front wall of the plenum chamber -arrow-.
Unlock the clamps from the wheel arch using a 5.5-pos. spanner. 1 - and remove the cable gland -2- upwards. Release the wiring harness -3- going to the alternator and starter using the release lever -80-200-.
Release the cable duct by unlocking the lock -arrow B- and moving the cable duct up -arrow A-.
Remove the vacuum connection -1- from the end wall of the plenum chamber; to do this, disconnect the vacuum hose -2- at the rear -arrow-.
Remove bolt -2- and nut -3-. Remove the filler neck -1- with the filler tube from the washer fluid reservoir by guiding it through the body opening -arrow-.
Unscrew the nut -5- and release the ground wire. Unscrew bolts -1,2,4- and remove cover -3- of the engine switching unit. compartment -arrow-.
Remove the fasteners -arrow A- and open the cover -arrow B- of the engine control unit.
If present, disconnect the electrical connection. connector -2-. Disconnect plug connectors -4- and unscrew electrical wiring -3-. Unlock the fasteners -arrow- and remove the pre-exhaust unit. B -SB- -pos. 1 -. Remove and release the engine wiring harness secured in the connection box.
Unlock latches -arrows A- and remove cable guide -2- upwards -arrow B-. Release the wiring harness, place it on the engine and secure the engine control unit from falling. -Pos. 1- do not take into account.
Remove vacuum hose -6-. Unscrew the nut -1-. Disconnect the coolant hoses by loosening the hose clamps -2- and -5- and pressing the retaining clips -4- and -3-. Remove the front wall of the drainage box.
Disconnect and unplug connector -1- for lambda probe -G39- and connector -2- for temperature sensor in front of diesel particulate filter. Disconnect el. connector -3- of exhaust gas pressure sensor 1 -G450-. -Pos. 4- ignore.
Unscrew nuts -1 -, remove bracket -2- and place to one side together with exhaust gas pressure sensor 1 -G450-.
Unscrew nuts -1, 2, 3- of the turbocharger and place the particulate filter back.
Disconnect and unplug connector -2- from reversing light switch -F4-. -Pos. 1.3 - do not take into account.
Unlock electrical cable -A- from gearbox and disconnect electrical connector -C-. -Pos. B-ignore.
Unscrew bolts -2...6- connecting the gearbox and engine. Disconnect the starter from the gearbox and leave it in its installation position. -Pos. A - ignore. Bolt -2- secures the starter to the gearbox and has an additional spacer sleeve -arrow-.
Install cross member -10-222 A- onto the shock absorber strut cups on the left and right, as shown in the illustration. Connect the gearbox and the lead screw with a weight bracket -10-222 A/12- and an additional hook -10-222 A/2-. For better installation representation, the position is shown with the engine removed. Lightly tighten the engine using a hose. of the traverse screw.
Remove the support eye -2024 A- by releasing 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 pin. Attach suspension device -2024 A- to the engine and service crane -VAS 6100- as shown in the illustration. The hooks and locking pins of the hanging fixture must be secured with stoppers.
Unscrew the left and right bolts -1- of the engine mount. Unscrew the nut -2- and remove the electrical wiring bracket. -Pos. 1 -and -arrow- do not take into account.
Raise the engine enough to release the engine mounts. Tighten the traverse lead screw -10-222 A-. Risk of damage to hose and cable connections as well as motor. compartment Make sure that all hose and wire connections between the engine, gearbox, subframe and body are disconnected. When removing the engine, carefully remove it from the engine. compartment
When removing the engine, the second mechanic must carefully open the hood, ensuring the maximum opening angle. To do this, lightly pry 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 out of the engine. compartment Reinstall the gas stops onto the ball studs.
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