Removing
All cars
1. Disconnect the wire "masses" from the battery.
For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).
2.
WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.
Raise and support the vehicle.
3. Remove the hood.
For more information, see chapter: Bonnet (501-02 Front body panels, Removal and installation).
4. Remove the cooling fan shroud.
For more information, see chapter: Cooling Fan Shroud (303-03 Engine cooling - Diesel engine ID4 2.4L, Removal and installation).
5. Remove the air filter.
For more information, please refer to the chapter: Air Filter (303-12 Intake air distribution and filtration - Diesel engine ID4 2.4L, Removal and installation).
6. Remove the catalytic converter.
For more information, see chapter: Catalytic Converter (309-00 Exhaust system - Diesel engine ID4 2.4L, Removal and installation).
7. Remove the starter.
For more information, see chapter: Starter (303-06 Starting system - Diesel engine ID4 2.4L, Removal and installation).
8. Disconnect the crankshaft position sensor from the transmission (CKP) and wiring harness for reversing lights. Release 3 clamps.
9. Disconnect an electric socket of the switch of lanterns of a backing.
10. Disconnect the reversing light switch harness from the transmission. Release the clamp.
11. Completely loosen the two lower power steering pump bolts.
12. Disconnect the coolant hose from the engine oil cooler. Release the clamp.
13. Disconnect the coolant hose of the EGR heat exchanger (EGR). Release the clamp.
Vehicles with air conditioning.
14.
CAUTION: Plug all openings. Use new caps.
Disconnect the A/C compressor refrigerant high pressure line (A/C). Remove and discard 2 o-rings.
All cars
15. Remove the inlet pipe of the charge air cooler. Loosen two clamps.
16. Disconnect the charge air cooler outlet hose. Loosen two clamps.
17. Disconnect the electrical connector of the engine wiring harness.
18. Disconnect the electrical connector for the glow plugs.
19. Release the engine wiring harness.
- Disconnect 3 electrical connectors from the engine control unit (ECM).
- Release 2 clips.
20. Disconnect the wiring harness from the coolant hose on the heater.
21. Disconnect the upper radiator coolant hose. Release the clamp.
22. Disconnect the 3 coolant hoses from the pump housing. Release 3 clamps.
23. Disconnect the vacuum line of the vacuum brake booster from the vacuum pump of the brake system.
24. Remove the accessory drive belt from the power steering pump pulley. Loosen the belt tension.
25. Remove the power steering pump.
- Remove the remaining bolt.
- Tie the power steering pump separately from other components.
26.
CAUTION: Plug all openings. Use new caps.
Disconnect 2 fuel lines. Release the fuel return line from the clamp.
27. Disconnect the heater coolant hose from the heater control valve. Release the clamp.
28. Disconnect the EGR heat exchanger coolant hose.
- Release the clamp.
- Disconnect the coolant hoses from the EGR heat exchanger.
29. Release the right engine mount.
- Remove the nut.
- Turn out two bolts.
30. Release the left engine mount.
- Remove the nut.
- Turn out two bolts.
31. Raise and support the car. Support the gearbox with a hydraulic jack.
32. Remove both engine mounts.
33. Turn out 5 left bolts connecting the engine with a transmission.
34. Turn out 5 right bolts connecting the engine with a transmission.
35. With the help of a second mechanic, carefully remove the engine.
Installation
All cars
1. With the help of a second mechanic, carefully install the engine. Clean the contact surfaces of the parts.
2. Attach the engine to the gearbox.
- Tighten the bolts (tightening torque 40 Nm).
- Remove the hydraulic jack from under the gearbox.
3. Install the left engine mount.
4. Install the right engine mount.
5. Attach both engine mounts.
- Lower the engine onto its supports.
- Tighten the bolts (tightening torque 80 Nm).
- Tighten nuts (tightening torque 80 Nm).
6. Connect the coolant hose of the EGR heat exchanger (EGR).
- Lock the clamp.
- Attach the coolant hoses to the EGR heat exchanger.
7. Connect the heater coolant hose to the heater control valve. Lock the clamp.
8.
NOTE: Remove and discard plugs.
Connect the fuel lines.
- Lock the clamp.
- Secure the fuel return line to the clamp.
9. Install the power steering pump.
- Remove and discard clamp.
- Tighten the bolts to 23 Nm.
10. Attach the accessory drive belt to the power steering pump pulley.
11. Connect the vacuum line of the vacuum brake booster to the vacuum pump of the brake system.
12. Connect the coolant hoses to the coolant pump housing. Lock the clamps.
13. Connect the upper radiator coolant hose. Lock the clamp.
14. Attach the engine wiring harness.
- Connect the electrical connectors of the engine control unit (ECM).
- Fasten the clamps.
15. Connect the electrical connector for the glow plugs.
16. Connect the electrical connector of the engine wiring harness.
17. Install the charge air cooler outlet hose. Tighten the clamps.
18. Install the charge air cooler intake duct. Tighten the clamps.
Vehicles with air conditioning
19.
NOTE: Remove and discard plugs.
Connect the A/C compressor high pressure line.
- Install new o-rings.
All cars
20. Replace the air filter.
For more information, please refer to the chapter: Air Filter (303-12 Intake air distribution and filtration - Diesel engine ID4 2.4L, Removal and installation).
21. Connect the coolant hose to the EGR heat exchanger. Lock the clamp.
22. Connect the coolant hose to the engine oil cooler. Lock the clamp.
23. Connect an electric socket of the switch of lanterns of a backing.
24. Attach the crankshaft position sensor harness (CKP) and reversing light switch to gearbox. Fasten with clamps.
25. Install the starter.
For more information, see chapter: Starter (303-06 Starting system - Diesel engine ID4 2.4L, Removal and installation).
26. Install the catalytic converter.
For more information, see chapter: Catalytic Converter (309-00 Exhaust system - Diesel engine ID4 2.4L, Removal and installation).
27. Install the cooling fan shroud.
For more information, see chapter: Cooling Fan Shroud (303-03 Engine cooling - Diesel engine ID4 2.4L, Removal and installation).
28. Connect the wire "masses" to the battery.
For more information, see the chapter: Connecting the Battery (414-01 Battery, Battery Mount and Wires, General Procedures).
29. Install the hood.
For more information, see chapter: Bonnet (501-02 Front body panels, Removal and installation).
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