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 1-9 and 11 of Section 4.
2. Pull out the lock (see illustration) and disconnect the coolant hose.
25.2. Coolant hose retainer.
3. Open the lid (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.
4. Remove the air hose (see illustration 4.16).
5. Disconnect the connector (3 in illustration 4.17), unscrew the bolts (1 and 2) and remove the throttle module from the intake manifold.
6. Place a cloth under the power steering pump to collect any leaking fluid. Clamp the hose with clamp No. 3094 (see illustration 15.5), loosen the clamp (1) and disconnect the hose from the pump. Cap the hose and pump to prevent dirt from getting into them.
Note: Do not remove the hollow bolt (2).
7. Unscrew the bolt (1 in illustration 4.19) holder, unscrew the bolt (3) and disconnect the refrigerant line from the air conditioning system compressor. Cap the refrigerant line and the corresponding compressor port to prevent dirt or moisture from entering the refrigerant circuit. Do not kink or stretch refrigerant lines.
8. Disconnect the coolant hose from the air cleaner cover (arrow in the illustration), disconnect the MAF sensor connector (2), loosen the clamp (3) and disconnect the air hose from the turbocharger. Release the latches (1).
25.8. Removing the air cleaner cover.
9. On models with air suspension, use a screwdriver to press the retaining ring (1 in illustration 4.24) forward from the connection. Press the ring (2) in the direction of the arrows and remove the ventilation hose (3) from the air cleaner cover. Remove the air cleaner cover and filter element.
10. Disconnect the air hoses at the locations (2 and 3 in illustration 4.21).
11. Remove the electrical wiring connector (see illustration) from the bracket and disconnect. Remove the connector bracket from the cylinder head cover.
12. Disconnect the vacuum hose going to the brake booster (see illustration 4.26 or accompanying illustration).
25.12. Clamp of the vacuum hose going to the brake booster (option 2).
13. Loosen the clamp (1 in the illustration) and disconnect the coolant hose from the expansion tank.
25.13. Expansion tank connections.
14. Disconnect the feed (1 in illustration 15.12) and return (2 and 3) fuel lines from the air intake chamber dividing panel.
Note: Fuel may remain hot for some time after the engine is turned off. When disconnecting fuel lines, wrap the connection with a thick layer of cloth and slowly disconnect.
15. Remove the electrical wiring connector from the bracket (2 in Illustration 4.2 of Chapter 4) lambda probe "G39", disconnect it and move it to the side.
16. On models with an SCR catalytic converter, disconnect the connector (see illustration 25.16a), unscrew the G295 NOx concentration sensor (see illustration 25.16b), and then move the wiring to the side.
25.16a. Electrical wiring connector.
25.16b. NOx concentration sensor.
Hang the sensor on the body.
17. Follow the steps in paragraphs 29-35 Section 4.
18. Remove the exhaust pipe bracket from the side member (see illustration 4.39)
19. On models without an SCR catalytic converter, unscrew the temperature sensor No. 3 "G495" in front of the particulate filter (see illustration 4.40), remove the clamp (see illustration) and disconnect the hose from the particulate filter that goes to the pressure difference sensor "G505" from the pressure pipe.
25.19. Hose clamp for the "G505" sensor.
20. On models with an SCR catalytic converter, disconnect the hoses from the diesel particulate filter (see illustration 4.41), going to the differential pressure sensor "G505" from the pressure pipes.
21. Remove the rear propeller shaft (see Chapter 7) and disconnect the steering gear wiring connector (see illustration 4.42).
22. Remove the soundproofing panel bracket (see illustration 4.37).
23. Pry up the cable head (1 in illustration 15.22) lever No. 80-200 and separate it from the selector mechanism lever. Unscrew the bolt (2) and remove the cable from the AT together with the bracket.
24. Unscrew the two bolts and remove the heat shield (And in illustration 4.43) steering mechanism. Set the front wheels in the straight ahead position and secure the steering wheel with tape to prevent it/steering column from changing position. Remove the hinge mounting bolt (B) and separate it from the steering gear.
25. Prepare to collect the power steering fluid and on the left side of the front panel, disconnect the power steering fluid line (see illustration 4.44), which goes to the power steering fluid radiator. Plug any open lines to prevent dirt from getting in
26. Unscrew the bolt (see illustration), disconnect the refrigerant line and set it aside.
25.26. Refrigerant line mounting bolt.
27. Follow the steps described in paragraphs 46-51 of Section 4.
28. Make sure that all wiring lines and connectors between the engine, AT, subframe and body are disconnected. Carefully lower the power unit together with the subframe from under the car, guiding it so as not to damage any parts. Direct the suspension struts behind the side members.
Separation of the engine from the AT
29. Secure the VAS6131/13-7 support to the threaded hole on the front side of the engine using an M 10x45 bolt (1 in the illustration) and nut (2).
25.29. Support under the front side of the engine.
Fix the support on the coordinate table with a force of 20 Nm.
30. Install supports from sets VAS6131/10, -/12, -/13 and -/14 under the front side of the AT and the front propeller shaft, as shown in Illustration 15.37. Secure support VAS6131/12-2 with bolt M10x35 (arrow) and washer.
31. Remove the bolts on the particulate filter and primary catalytic converter brackets (see illustrations 4.58a-b).
32. Give me the nuts (see illustration) and remove the primary catalytic converter with the diesel particulate filter.
25.32. Fastening the catalytic converter and diesel particulate filter assembly.
33. Move the coolant hoses to the side (see illustration 15.30).
34. Disconnect the coolant hose (1 in the illustration), unscrew the bolts (arrows) and move the hose on the left side of the AT to the side.
25.34. Coolant pipe fastening.
35. Turn out the swamp (1 in the illustration) and loosen the bolt (3).
25.35. Removing the valve "N488" of the AT cooling system.
Press back the bracket (2) with the coolant valve "N488" for cooling the automatic transmission.
36. Loosen the clamps (2 and 4 in the illustration), lift the retainer (3) and disconnect the coolant hoses.
25.36. Coolant line connections.
Remove the bolts (arrows) and disconnect the coolant pipe from the left side of the AT.
37. Unscrew the bolts securing the front propeller shaft to the transfer case (see illustration 4.65).
38. Remove the bolts (1-3 in the illustration) and disconnect the ATF lines from the AT.
25.38. ATF line connections.
Cap any open lines and ports to prevent dirt from entering the ATF circuit.
39. Unscrew the bolt (see illustration 4.67) ATF line bracket.
40. Loosen the drive belt tension by turning the tensioner in the direction of the arrow (see illustration) torx T60 head.
25.40. Fixing the drive belt tensioner.
Remove the belt from the compressor pulley and lock the tensioner with the T10060A locking pin. If the belt is to be reinstalled, mark its direction of rotation first so that it can be reinstalled in the same manner. Remove the plug (8 in illustration 27.1) from the intermediate pulley (10), unscrew the bolt (9) and remove the pulley.
41. Follow the steps described in paragraphs 69-73 of Section 4.
42. Remove the cover (2 in the illustration).
25.42. Cover (2) and bolts (1) for fastening the torque converter.
Mark the position of the torque converter relative to the drive plate. Then, through the opening for the starter, unscrew the 6 bolts (1) securing the torque converter, holding the crankshaft from turning by its central bolt. To access each subsequent pair of torque converter mounting bolts, rotate the crankshaft 120°.
43. Remove the bolts (3-10 in illustration 15.45) fastening the AT to the engine. Separate the AT from the engine by moving the coordinate table apart: the engine is supported by four supports on one part of the table, and the AT is also supported by four supports on the other part of the table. At the same time, separate the torque converter from the drive disk through the opening for the starter.
44. Finally, secure the torque converter in the AT with tool No. 30-211A so that it does not fall out (see illustration 4.77).
45. To lift the engine from the coordinate table, use a suitable hoist hooked onto the lifting eyes (see illustration).
25.45. Engine lift.
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.
46. Make sure that the AT centering bushings are present in the cylinder block (And in the illustration 15.45): install them if necessary.
47. Install the torque converter in the AT (see Chapter 6) and make sure it is located at a distance (and in illustration 4.80) from the torque converter flange. For the 0C8 torque converter, this distance should be 23 mm. If the torque converter is not fully installed, this distance will be approximately 11 mm.
48. Follow the steps described in paragraphs 81-82 of Section 4.
49. Further installation is carried out in reverse order. Please note the following features.
50. The tightening forces for the AT fasteners to the engine are indicated in the captions to illustrations 15.45. 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.
51. Please take note of the information provided in paragraphs 85-87 of Section 4.