Engine and Manual Transmission, Separating

Engine and Manual Transmission, Separating

Special tools, testers and auxiliary items required

• Scissor-Type Assembly Platform (VAS 6131 A)

• Support Set (VAS 6131/10) , Supplementary Set (VAS 6131/13-7) and Gearbox Support (VAS 6131/14)

• Socket (T40058)

Procedure






• Engine/transmission assembly removed and placed on (VAS 6131 A).

- Remove the electrical connector - 3 - for the Oxygen Sensor (O2S) 2 after catalytic converter (G131) from the bracket and disconnect it.

• Ignore - 1 and 2 -.

- Remove the bolt - 1 - and the nuts - arrows - and then remove the left catalytic converter.






- Remove the connector - 1 - for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) (G130) from the holder and disconnect it.






• Ignore - 2 and 3 -.

- Remove the bolt - 1 - and the nuts - arrows - and then remove the right catalytic converter.






- Disconnect the connector - 2 - from the Engine Speed (RPM) sensor (G28).






• Ignore - 1 -.

Vehicles with Electro-Mechanical Power Steering






- Disconnect the connector - 1 - from the power steering control module (J500).

- Free up the wiring harness.

• Ignore - 2 -.

- Remove the bolt - arrow - and move the coolant recirculation pump (V50) to the side.






All Vehicles






- Disconnect the connector - 2 - from the gear recognition sensor (G604).

• Ignore - 1 and 3 -.

- Remove the left and right drive axles from the transmission flange shafts.






- Remove the lower cover - 1 - from the transmission - arrow -.






- Insert the (T40058) guide pins as follows:






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the adapter.

- Counter hold the crankshaft and loosen the drive plate bolts using a (T40058) and a ring wrench.






• The crankshaft may be turned only in the direction of engine rotation - arrow -.

- Remove the 6 bolts - arrow - on the clutch module. Turn the crankshaft an additional 60° in the direction of engine rotation.






- Equip the (VAS 6131 A) with the (VAS 6131/10) , (VAS 6131/13-7) and (VAS 6131/14) as follows:






• The other attachments remain unchanged.






- Install the (VAS 6131/13-7) at the right front of the engine in the threaded hole as shown in the illustration.






- Install the (VAS 6131/13-7) on the scissor lift table and tighten it to 20 Nm.

- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/14) at the front of the transmission as shown in the illustration.






- Rotate the left and right spindles up until the (VAS 6131/14) rests firmly against the transmission.

- Attach mounting element base plates to the (VAS 6131 A) and tighten to 20 Nm.

- Remove the starter bolts - 1 and 2 -.






- Press the starter off the transmission and leave it in the installation position.

- Remove the remaining bolts - 3 through 11 - that attach the engine to the transmission.

• Ignore - A -.

- Loosen clamping bolts - 1 - on sides of the (VAS 6131 A) and pull the rear table plate with the transmission toward rear - arrow -.