Note: The engine is removed together with the AT and subframe from under the engine compartment (with the front panel installed), and then separated from the transmission.
Removal
1. Follow the steps described in paragraphs 1-5 of Section 4.
2. Lift the clamps (see illustrations) and disconnect the air hoses from the intercooler.
35.2a. Air hose retainer (1) on the left side of the intercooler.
35.2b. Air hose retainer (arrow) on the right side of the intercooler.
3. Prepare to collect the leaking coolant. Remove the plug (see illustration) and drain the coolant.
35.3. Coolant drain plug.
4. Disconnect the coolant hose (1 in the illustration) from the radiator.
35.4. Coolant hose (2) on the radiator.
On BTR/CCFA engines, disconnect the coolant hose (1) from the coolant pipe leading to the auxiliary radiator.
5. On models with a 4-zone climate control system, disconnect the hoses from the coolant pipes of the heater radiator and allow the fluid to drain (see illustration 4.9).
6. On CCFA/CCFC engines, disconnect the coolant hose (2 in the illustration), and on BTR/CCFA engines, disconnect the coolant hose (1) going to the auxiliary radiator.
35.6. Clamps for coolant hoses (1 and 2) and power steering hose (3).
On all engines, disconnect the power steering fluid hose leading to the power steering fluid radiator. Plug any exposed holes to prevent dirt from getting in.
7. Disconnect the refrigerant line (1 in the illustration) from the condenser and seal the open holes to prevent dirt from getting into them.
35.7. Fastening the refrigerant lines to the condenser.
8. Unscrew the bolt (see illustration) and disconnect the refrigerant line.
35.8. Refrigerant line fastening.
9. Unscrew the bolt (see illustration 4.46) and disconnect the ATF lines from the ATF temperature regulator. Plug the exposed holes to prevent dirt from getting in.
10. Remove the upper engine cover and the upper radiator shroud (see Section 19 of Chapter 1).
11. Disconnect the connector (1 in the illustration) from the bracket and disconnect.
35.11. Connector (1) and tie (arrow) for electrical wiring.
Remove the tie (arrow) and remove the wiring from the air cleaner.
12. Remove the air cleaner cover as described in paragraphs 10-13 Section 16 Chapter 1.
13. On the BTR engine, disconnect the vacuum hose (2 in the illustration) from the vacuum receiver.
35.13. Hose connections.
On all engines, disconnect the vacuum line (1) to the brake booster and disconnect the coolant hose (3) from the right rear coolant pipe.
14. Remove the electrical wiring connectors (1-3 in the illustration) from the bracket, disconnect and move the wiring to the side.
35.14. Electrical wiring connectors.
15. Loosen the clamp (1 in the illustration) and disconnect the air hose from the throttle body module "J338".
35.15. Air hose fastening.
16. Loosen the clamp (see illustration), disconnect the coolant hose and move it to the side.
35.16. Coolant hose clamp.
17. On the BTR engine, disconnect the connector (2 in the illustration) refrigerant pressure and temperature sensor "G395".
35.17. Electrical wiring connector (2) of the "G395" sensor.
18. On the CCFC engine, loosen the nuts (arrows in the illustration), move the wiring away from the engine and place it on the left side.
35.18. Electrical wiring fastening nuts.
19. Loosen the clamp (1 in the illustration) and disconnect the air hose from the throttle body module "J544" No. 2.
35.19. Air hose fastening.
20. Lift the clamp and disconnect the coolant hose from the radiator (see illustration).
35.20. Coolant hose retainer on the radiator.
21. Loosen the clamp (1 in the illustration) and disconnect the air tube from the left air cleaner cover.
35.21. Removing the left air cleaner cover.
Disconnect the connector (2) of the MAF sensor No. 2 "G246", release the clips (3) and remove the air cleaner cover.
22. On BTR/CCFA engines, disconnect the coolant hoses from the coolant pipes (arrows in the illustration).
35.22. Fastening and connections of coolant hoses.
23. On BTR/CCFA engines, disconnect the supply line from the fuel filter (2 in the illustration) and return (1) fuel hoses.
35.23. Fuel filter fasteners and connections.
Remove the bolts (arrows) and nut (3). Seal the exposed hoses and ports to prevent dirt from entering the fuel system. Move the fuel filter to the side without disconnecting the other fuel lines.
24. On BTR/CCFA engines, remove the bolts (1-4 in illustration 4.14), but do not remove the fuel filter bracket. Then open the lid (arrow in illustration 4.15) terminals B+ and disconnect the positive wire (1) going to the starter and generator
25. On CCFC engines, open the cover (arrow in illustration 15.4) terminals 30, unscrew the bolt (1), remove the stud (2) of the positive battery terminal and move it to the side.
26. On CCFC engines, disconnect the fuel hoses (see illustration).
35.26. Fuel line connections.
Seal any open hoses and ports to prevent dirt from entering the fuel system.
27. Disconnect the hose from the power steering fluid reservoir (see illustration).
35.27. Hose on the power steering fluid reservoir.
Seal any open hoses and ports to prevent dirt from entering the power steering fluid circuit.
28. Remove the air intake chamber cover (see Section 19 of Chapter 1) and the electronics compartment cover (see illustration 4.29).
29. In the electronics compartment, disconnect the connectors (1-3 in illustration 4.30) and move the wiring to the side.
30. Disconnect the ground wire (arrow in the illustration) and remove the ECM (1 and 2 in the illustration), as described in Chapter 5.
35.30. ECM modules.
31. Follow the steps described in paragraphs 32-37, 42-43, and 47-48 of Section 4.
32. Separate the exhaust system with clamps (1 and 2 in the illustration).
35.32. Exhaust pipe clamps.
Note: Do not bend the flexible sections of the exhaust system more than 10°.
33. Remove the bolts (1 in the illustration).
35.33. Fastening of the left diesel particulate filter.
34. Remove the bolts (5 in the illustration).
35.34. Fastening of the right diesel particulate filter.
35. If the engine will be separated from the AT after removing the power unit assembly, remove the connector (5 in the illustration) from the bracket (5).
35.35. Connector (2) and bracket fastener.
Unscrew the bolts (1 and 4), remove the nut (3), separate the bracket and remove the hexagonal stud installed behind it.
36. Follow the steps described in paragraphs 49-51 of Section 4.
37. Make sure that all lines and connectors of electrical wiring between the engine, AT, subframe and body are disconnected. Carefully lower the power unit together with the subframe from under the car by 250 mm (see illustration 4.52), directing it so as not to damage any parts. Direct the suspension struts behind the side members.
38. Remove the bolts (3 in the illustration), loosen the bolt (1) and remove the heat shield (2) of the selector cable.
35.38. Fastening of heat shield of selector cable.
39. Press the hinge (2 in illustration 4.54) the selector cable from the selector mechanism lever using lever No. 80-200. Then pull out the lock (1) and remove the selector cable from the AT without bending it. Lower the power unit completely.
Separation of the engine from the AT
40. Remove the connectors (1 and 2 in the illustration) exhaust gas temperature sensors "G235" and "236" from the bracket, disconnect them and move the wiring to the side.
35.40. Connectors of sensors "G235" and "G236" on the bracket.
41. Disconnect the connector (2 in the illustration) differential pressure sensor No. 2 "G524".
35.41. Connectors of sensors "G524" and "G498" (2 and 3).
Remove the connector (3) of sensor No. 2 "G498" of the temperature in front of the particulate filter from the bracket, disconnect it and move the wiring to the side.
42. Remove the connector (1 in the illustration) sensor No. 2 "G448" exhaust gas temperature from the bracket, disconnect and move the wiring to the side.
35.42. Connectors of sensors "G448" and "G505" (1 and 2).
Disconnect the connector (2) of the differential pressure sensor "G505" and move the wiring to the side.
43. Give me the nuts (arrows in the illustration) and unscrew the bolts (1) securing the left catalytic converter.
35.43. Left catalytic converter fastener.
Remove the bolts (2 in illustration 35.33) and disconnect the hose (3) going to differential pressure sensor No. 2 "G524". Remove the left diesel particulate filter and catalytic converter.
44. Give the nut (1 in the illustration), unscrew the bolt (3) and remove the wiring connector bracket.
35.44. Fastening brackets (1 and 3) and connections of coolant hoses.
Move the AT ventilation hose (2) to the side. Disconnect the coolant hoses from the rear left coolant pipes (top arrows). Move the rear right coolant pipes to the side without disconnecting the hoses from them (bottom arrows).
45. On CCFA/CCFC engines, disconnect the connector (arrow in the illustration), unscrew the bolt (3) and put aside the speed sensor No. 1 "G653".
35.45. Connector (arrow) and fastening (3) of sensor "G653".
46. Remove the bolts (1 in the illustration) on the turbocharger bracket, on the left side.
35.46.Fastener of the left turbocharger bracket.
47. Loosen the nuts (arrows) and unscrew the bolts (1) of the right catalytic converter. Remove the bolts (4 in illustration 35.33) and disconnect the hose (1) going to the differential pressure sensor "G505".
35.47. Fastening of the right catalytic converter.
Remove the right diesel particulate filter and catalytic converter.
48. Remove the bolts (2 in the illustration) on the right turbocharger bracket.
35.48. Fasteners for the right turbocharger bracket.
49. Disconnect the connector (5 in the illustration) and unscrew the bolt (1).
35.49. Removing air tubes (right side).
Loosen the clamps (2 and 4) and remove the right air tubes.
50. Unscrew the bolt (1 in the illustration), loosen the clamp (arrow) and remove the right air tube together with the air hose forward.
35.50. Air tube fastener (right side).
51. Place supports VAS6131/10 and -/11 under the front right side of the engine as shown in the illustration.
35.51. Supports under the front right side of the engine.
Select the motor weight on the spindles.
52. Give the nut (arrow in the illustration) and unscrew the bolts (1) of the right engine support.
35.52. Fastening of the right engine support.
53. Unscrew the bolts and remove the right engine mount together with its bracket (see illustration).
35.53. Fastening the right engine support bracket.
54. Remove the bolts (1 in the illustration) mass connections.
35.54. Starter connections and fasteners.
Remove the caps and nuts (3 and 4) securing the electrical wiring. Remove the bolts (2 and 5) and remove the starter.
55. Insert the guide pin of the T40058 adapter with a larger diameter (2 in illustration 4.73a) outward, and with a smaller diameter (2) - into the adapter.
35.55. Keeping the crankshaft pulley from turning.
Hold the crankshaft from turning by installing the adapter assembled in this way on the center of the crankshaft pulley (see illustration).
56. Remove the cover (1 in the illustration) in the forward direction.
35.56. Cover (1) and bolts (2) for fastening the torque converter.
Mark the position of the torque converter relative to the drive plate. Then unscrew the 6 bolts (arrows) securing the torque converter through the opening for the starter, holding the crankshaft from turning by its central bolt. To access each subsequent pair of torque converter mounting bolts, rotate the crankshaft 120°.
57. Install the right engine mount together with its bracket. Drive the stand spindles under the front right side of the engine as low as possible and remove the stands from the x-axis table (see illustration 35.51).
58. Remove the bolts (1 and 2 in the illustration) and disconnect the ATF lines from the AT.
35.58. ATF line fasteners.
Collect leaking ATF with a cloth.
59. Unscrew the bolts securing the front propeller shaft to the transfer case (see illustration 4.65).
60. Install the VAS6131/13-7 support under the front side of the engine using the M 10x55 bolt (1 in the illustration) and nuts (2).
35.60. Support under the front right side of the engine.
Fix this support to the coordinate table with a force of 20 Nm.
61. Install supports under the AT and under the front propeller shaft. as indicated on illustrations 4.56 and 4.57.
62. Unscrew the remaining bolts securing the AT to the engine (see illustration).
35.62. Bolts for fastening the AT to the engine:
A - Centering bushings;
1 - Bolt M10x40, 45 Nm;
2 - Bolt M10x70, 45 Nm;
3-6 - Bolt M12x80, 80 Nm;
7 - Bolt M12x140, 80 Nm;
8, 10, 11 - Bolt M12x70, 80 Nm;
9 - Hexagon head stud M12x70, 80 Nm.
63. Separate the AT from the engine by moving the coordinate table apart: the engine is supported on four supports on one part of the table, and the AT is also supported on four supports on the other part of the table. At the same time, separate the torque converter from the drive disk.
64. Finally, secure the torque converter in the AT with tool No. 30-211A so that it does not fall out (see illustration 4.77).
65. To lift the engine from the coordinate table, use a suitable hoist hooked onto the lifting eyes (see illustration).
35.65. Engine lifting.
Installation
Note: Place the hoses and wiring in the same position as they were before removal; install all clamps and ties in their original places.
66. When connecting the engine to the AT, bring the ATF lines into the installation position and install the power steering fluid line.
67. Install the engine mounts together with their brackets.
68. Make sure that the AT centering bushings are present in the cylinder block; install them if necessary. In addition, the centering sleeve must be installed in the crankshaft (see illustration 4.79).
69. Make sure that there is an O-ring in the power steering pump wire shaft (see illustration).
70. Install the torque converter in the AT (see Chapter 6) and make sure it is located at a distance (a in illustration 4.80) from the torque converter flange. For the AT "09D", this distance should be 22 mm, and for the AT "0C8" - 23 mm. If the torque converter is not fully installed, this distance will be approximately 10 or 11 mm (for the AT "09D" or "0C8", respectively).
71. Rotate the torque converter and drive plate so that the holes for the mounting bolts are in the opening for the starter.
72. Connect the engine to the AT, install the cover (1 in illustration 35.56) and secure the torque converter to the drive plate with new knurled bolts (it is recommended to use original bolts), tightening them to 85 Nm. While tightening the bolts, hold the crankshaft from turning (see paragraph 55).
Note: Before and while tightening the torque converter mounting bolts to the engine, always ensure that the torque converter can be rotated. If the torque converter does not turn, the final tightening of the bolts will damage the drive lugs of the ATF pump and, consequently, the torque converter.
73. Further installation is carried out in reverse order. Please note the following features.
74. The tightening forces for the AT fasteners to the engine are indicated in the captions to Illustration 35.62. Tighten other threaded fasteners M6/M7/M8/M10/M12 with forces of 9/15/20/40/65 Nm, respectively.
Note: Torques are given with a tolerance of ±15% for lightly lubricated, phosphated or black fasteners. Do not remove factory grease from fasteners. Additional lubrication with engine or transmission oil is permitted, but not with graphite-containing lubricants.
75. Perform the steps described in paragraphs 85-87 of Section 4.
This article was previously published on the resource AudiManual.ru