 printable version
Refitting
Procedure: - Disconnect from the AB terminal "-", then "+"; - Remove the AB;
| Fig. 18. Removing AB: 1 - a casing of the air duct; 2 - partition
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- Remove the battery compartment bulkhead (see. Fig. 18); - Putting the front of the car to protect the engine, remove the support;
| Fig. 358. Removal of the charge air hose and air vent. The arrows indicate the place of disconnection
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- Disconnect the right charge air hose (Fig. 358) from the charge air cooler. Unscrewing two bolts, remove the vent air supply to the radiator cooling air discharge;
| Fig. 359. Fitting connection hose left the charge air cooler to the combustion air (arrow)
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- Disconnect the hose left (Fig. 359). Remove charge air pipe from the holder on the gearbox; - Disconnect the wires from the starter: Disconnect plug connector (terminal "50"), disconnect the cable (terminal "30") and remove the cable clamp; - Lower the car on the ground; - Drain the coolant from the cooling system as described for the petrol engine. It is best to disconnect the bottom of the hose; - Remove the headlamp; - Remove the upper part of the air filter;
| Fig. 360. Removing the top of the air filter: 1 - a hose; 2 - intake manifold; 3 - Plug block the air flow sensor; 4 - lock
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- Disconnect the hose 1 (Fig. 360), going to the vacuum regulator EGR and disconnect the inlet pipe 2; - Disconnect plug connector 3 air flow sensor; - Disconnect the three latch 4;
| Fig. 361. The point of attachment of the upper charge air hose (arrow)
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- Remove the lower part of the air filter. To do this, squeeze the holder of the first outer side walls. Disconnect the upper hose discharge air (Fig. 361), after loosening the hose clamp.
| Fig. 362. Remove engine cover. Attaching the cover indicated by the arrow
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| Fig. 363. Location of hoses: 1 - to boost pressure regulator in the control unit; 2 - charge air; 3 - coolant (in the expansion tank); 4 - Plug block the intake air temperature sensor; 5 - upper coolant hose
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- Disconnect shown in Fig. 363 hoses and plug-in connector; - Disconnect the vacuum hose from the intake pipe of the turbocharger and exhaust gas recirculation valve (the valve EGR); - Disconnect the fuel lines and the vacuum line from the vacuum pump; - Disconnect the electric cable from the generator and disconnect the plug of the high pressure fuel pump (pump);
| Fig. Disconnect the electrical pads 364: 1, 2 - crankshaft position sensor; 3 - the engine wiring harness
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- Disconnect plug blocks 1 and 2 (Fig. 364), crankshaft position sensor, the plug connector of the engine wiring harness 3. To do this, remove the appropriate spring clamps to release the cord; - Disconnect plug connector Switch reversing lamps; - Disconnect "mass" cable from the gearbox. Disconnect the pipe coupling system, which remove the spring clamp and release the clutch. Plug the open ends of the pipes;
A warning In operation pay attention to the flow of fluid. |
- Disconnect the coolant hoses going to the expansion tank and heater; - If the car has air conditioning, then disconnect the plug connector of the electromagnetic clutch; - Loosen the V-ribbed belt, as will be described hereinafter; - Loosen the wheel bolts. Replace the front part of the car on support and remove the front wheels; - Remove the front right wheel suspension:
| Fig. 365. The suspension of the front wheel. 1 Connecting rod stabilizer bar connects to the shock absorber
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- Disconnect the brake hose and remove the ABS sensor cable (shows the frequency of rotation of the wheel) from the holder on the shock absorber; - Loosen the nut of the bolt tie rod on steering pitman arm and remove the hinge by means of a stripper with a bipod vehicles; - Unscrew the bottom of the wheel suspension two bolts and press the ball joint suspension of the wheel bearing housing (knuckle); - Perform operations described on the left side of the vehicle;
| Fig. 366. Removing steering. Tie rods steering left and right by means of the wire loops, so that they do not fall
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- Tie the wire tie rods, as shown in Fig. 366, to both shock absorber. Now unscrew the steering of the crossbar, and the rod will remain hanging on the wire; - Unscrew the counterweight suspension Transmission;
| Fig. 367. The transverse beam front suspension is mounted in locations indicated by the arrows
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- Substitute the jack with a suitable support under the crossbeam, raise the jack so that it raised the crossbeam, and remove it in the locations shown in Fig. 367; - Drain the gear oil. Clean the plug and then screw it back immediately;
| Fig. 368. Remove the thrust bearing 1 of the right drive shaft and squeeze the shaft of the gearbox shown in place of 2
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- Remove the gearbox drive shaft right wheel. First, unscrew the thrust bearing 1 (Fig. 368), and then pull the shaft in place 2 of spline with the gearbox.
A warning In operation, the vehicle must be mounted on the supports. |
| Fig. 369. Removal of the left drive shaft
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Remove the left wheel drive shaft inserted using the mount (Fig. 369). Disconnect the shift cable from gearbox. The ends of the cables are secured with latches. After removing the clamps pull the two cable upwards out of their holders.
| Fig. 370. Reception pipe attached catalyst in locations indicated by the arrows
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Remove the three screws (Fig. 370) and separate from the exhaust pipe flange catalyst. Disconnect the exhaust pipe from the turbocharger (4 screws). Disconnect the hose from the heating pipe (hose connection).
| Fig. 371. Disconnect hoses from turbocharger 1 and 2 - the vacuum box and liberate them from the mounts
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Disconnect hoses from turbocharger 1 (Fig. 371) and the vacuum box 2 and release them from the hose mounts. Remove pipe holder power steering pump (located within walking distance from the pulley on the crankshaft). Remove the power steering pump pulley. To fix the pulley in a fixed position, insert the appropriate Allen key into the interior of the pump shaft. Remove the bolts from the power steering pump (one of the bolts located in the lower part), you remove the pump, take him aside and tie wire.
| Fig. 372. Removing air conditioner compressor
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If the car is equipped with air conditioning, remove the compressor. First, turn using a wrench 1 (Fig. 372) of the drive belt tension roller in the direction shown by the arrow, so that the drive belt weakened. Then unscrew bolts 2 and 3 and remove the compressor so as to avoid damage while any piping.
A warning Pipelines do not disconnect. |
Place a jack under the powertrain.
A warning Make sure that the power unit is well fixed. |
Remove the four bolts of the rear engine mount.
A warning Once again, check that the motor is securely fastened. |
Note At the service station to raise motor a special device, which is then substituted by a car lift. In Fig. 21 has been shown as a motor supported from below, i.e. It is reliably prop engine jack to it after loosening the attachment of the suspension of the engine remained in the same position. To ensure this, you need to have at their disposal a valve with manual transmission. Position the crane boom over the engine compartment and secure the drive with the help of the lifting loops on the hook of the crane. If you accidentally slip off the jack, then the arrow will keep the engine in the same position. |
| Fig. 373. Mounts front support (indicated by arrows)
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Slowly lower the engine down. To do this, you need an assistant, which will lower the vehicle jack or a crane, while you will continuously monitor the process of lowering the engine through the engine compartment. If the engine for anything hooked, it should be freed immediately to avoid damage to body parts or other components and assemblies. This is especially true shot and tie details. In addition, if possible, you can lift the front of the car to have more space for the removal of the engine. Engine installation is carried out in sequence, return to removal process, but should pay attention to the following points: - Check for wear on the clutch release bearing in the clutch slave cylinder. If necessary, replace the slave cylinder with clutch release bearing. On cars considered in the book should always be changed together; - Apply to the splined shaft clutch a little lubricant. Volkswagen recommends using this site lubrication with a designation G 000 100; - Set the engine and gearbox to the correct position in the engine compartment of the motor. With the rise of the power unit please note that it does not hit a drive shafts and always make sure that the engine together with the gearbox is well fixed on the jack or hoist. As already mentioned, it is convenient to use a valve with manual drive and arrow; - After the engine is aligned with the suspension mounting of the engine, tighten the bolts (about 5-6 turns). Few engine shake from side to side (it should not yet be finally dragged) and tighten the front and rear suspension mounting of the engine. Tighten the front beam suspension and a rear suspension bracket to 55 Nm (front hydraulic bearing). Install drive shafts and tighten bolts the corresponding moment. Tighten the power steering pump to 25 Nm. Do not forget the screw at the bottom fastening of the pump. Set the pump pulley, fixing the stationary shaft of the power steering pump with an Allen key and tighten the three bolts to 23 Nm. Tighten the bracket, the pipe retaining the power steering pump (20 Nm). When installing a turbocharger on the exhaust pipe, and at the junction of the exhaust pipe and a catalyst using new gaskets. Insert the drive shaft right wheel in the gearbox and tighten the thrust bearing (27 Nm). Before installation of the left wheel drive shaft replace thrust ring disposed on the shaft end. Reinstall the crossmember in the correct position and tighten as shown in Fig. 367 four bolts to 110 Nm. Set the equalizer suspension on the gearbox. Tighten the bolt on the outside of the torque 95 Nm. Remove steering with wire and attach to the bottom of the crossbar. The bolts are tightened to 50 Nm. Set the wheel suspension (see. Fig. 365). Tighten both bolts of the ball joint torque 55 Nm nut hinge tie rod torque 30 Nm nut connecting rod tighten to 100 Nm. Spend described operation on both sides of the car. Lower the car to the ground and tighten the wheel bolts (140 Nm). Put the V-ribbed belt, release the tension roller, that he pulled the belt. Connect the pipe to the clutch slave cylinder and secure it with a spring clip. Bleed the clutch system. Set the details of the air filter in the reverse order with respect to the process of withdrawal.
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