Automatic Transmission 09D

Engine and Automatic Transmission, Separating

Special tools, testers and auxiliary items required

• Support Set (VAS 6131/10) and Supplementary Set (VAS 6131/12) and (VAS 6131/13)

• Bracket (30 - 211 A)

• Socket (T40058)

• M10 x 45 bolt and nut

Procedure

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






- Equip scissor-type assembly platform (VAS 6131 A) with support set (VAS 6131/10) and supplementary set (VAS 6131/12) and (VAS 6131/13) as follows:

• The other attachments remain unchanged.






- Secure the front joint support (VAS 6131/13-7) into the threaded holes in the engine with a M10 x 45 bolt - 1 - and nut - 2 -.






- Install the joint support on the (VAS 6131 A) and tighten it to 20 Nm.

- Attach mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the front under transmission ATF oil pan as shown in the illustration.






- Prepare mounting elements from (VAS 6131/10) , (VAS 6131/12) and (VAS 6131/13) for supporting the driveshaft as shown in illustration.






- Remove the particulate filter bracket bolts - arrows -.






- Remove the bolt - arrow - on the preliminary catalytic converter strap.






- Remove electrical connectors from the bracket and disconnect.






1. For catalyst temperature sensor 1 (G20) (orange) - only engines meeting emissions standard BIN 5

2. For exhaust gas temperature 3 (G495) (brown)


- Free up electrical wires.

- Remove the bolts - 1 - and - 2 - and then remove the heat shield from the turbocharger.






- Remove the nuts - arrows - and then remove the preliminary catalytic converter and particulate filter.






- Free up the coolant hoses - arrow -.






- Loosen hose clamp - 2 - and lift clamp - 4 - to remove the coolant hoses.






- Free up the transmission vent hose - arrow -.

- Remove the bolts - 1 - and - 3 -; then remove the left coolant pipe on the back of the transmission.

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






- Remove the bolts - arrows - that attach the front driveshaft to the transfer case.






• Place a cloth underneath to soak up any escaping ATF.

• Observe the rules of cleanliness for working on automatic transmissions.

- Remove the bolts - 1 - and - 2 - and then remove the ATF lines from the transmission.






- Remove the generator - 1 -.






- Remove the starter.






- Insert the (T40058) guide pins as follows:






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

• Small diameter - arrow 2 - points to adapter.

- To loosen the torque converter bolts, counter hold the crankshaft using the (T40058).






Components could be destroyed by the camshaft timing chain jumping off.

• Only turn the crankshaft in the direction of engine rotation - arrow -.

- Remove the cover - arrow -.






- Turn the crankshaft 120° in the direction of engine rotation and remove the 6 torque converter bolts - arrows - inside the opening of the starter.






- Remove the transmission/engine bolts - 3 through 10 -.






- Remove the plug.

- Press the transmission off the engine, which also presses the torque converter off the drive plate - arrow -.






- Loosen the side bolts - 1 - on the (VAS 6131 A) and pull the rear table plate and transmission slightly toward the rear.






- Secure torque converter in transmission against falling out with the (30 - 211 A).