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 Transmission Support (VAS 6131/14)

• Adapter (T40257)

• Wrench (T40263)

• Jointed Socket, 12 mm (T40220) for engines through engine serial number CAU 005 521

• M10 x 65 bolt

Procedure






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

- Remove the electrical connectors from bracket and disconnect:

2 For Heated Oxygen Sensor (HO2S) 2 (G108)
3 For Oxygen Sensor (O2S) 2 after catalytic converter (G131)

• Ignore - 1 and 4 -.

- Remove the nuts - arrows - using the (T40220).






- Remove the bolt - 1 - and the left catalytic converter.

- Remove electrical connectors from bracket and disconnect:






2 For Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) (G130)
3 For Heated Oxygen Sensor (HO2S) (G39)

• Ignore - 1 and 4 -.

- Remove the nuts - arrows - using the (T40220).






- Remove the bolt - 1 - and the right catalytic converter.

- Disconnect the electrical connectors - 1 - leading to the steering gear - 2 - and on the Engine Speed (RPM) sensor (G28) and free up the electrical wires.






- Disconnect electrical connector - 2 - on the back-up lamp switch (F4).






• 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 -.






- Attach the (T40257) to the (T40263).






- Attach the adapter to the bolts on the vibration damper.

• The notch - arrow A - on the (T40257) must face the color dash - arrow B - on the vibration damper.

• Ignore the semi-round countersink on the adapter.

• When mounting, turn the crankshaft only in the direction of engine rotation - arrow -.

- Remove the 6 drive plate bolts - arrow - while turning the crankshaft 60° further 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.






- Connect the right front (VAS 6131/13-7) to the engine using the MD bolt in 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 the sides of (VAS 6131 A) and pull the rear table plate with transmission toward the rear - arrow -.