Engine, Removing
Engine, Removing
Special tools and equipment
- 10-222A engine support bridge
- 10-222A/1 bracket for engine
- 2024A engine sling
- 2024A/1 adaptor and 2024A/2 extension
- 3147 engine support adaptor
- 3204 drift
- VAG1202A work shop crane
- VAG1306 drip tray
- VAG1921 pliers for spring type clips
- M5 x 60 bolt
- 15 mm socket Matra V175 (for vehicles with automatic transmission)
Removing
Note:
- All tie wraps that are loosened or removed during engine removal must be replaced or reinstalled in the same positions when the engine is reinstalled.
- The engine is removed toward the front without the transmission.
- Drain coolant into a clean container for recycling or reuse.
- Run wipers to vertical position.
CAUTION! Before disconnecting the battery, determine the correct coding for the antitheft radio.
- Switch ignition off and disconnect battery Ground (GND) strap.
WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.
- Open cap on coolant expansion tank.
- Remove front bumper. Service and Repair
- Remove noise insulation panel (arrows).
- Unbolt cooling coil for power steering fluid (arrows) and let hang free. Do not open hydraulic fluid system.
- Loosely reinstall outside temperature display sensor bracket.
- Place VAG1306 drip tray underneath engine.
- Turn radiator drain plug counterclockwise (arrow): if needed, attach accessory hose to connection flange.
- Remove hose clamp from lower coolant hose at bottom of radiator and disconnect coolant hose.
CAUTION! Dispose of used coolant properly.
- Open coolant pump housing drain plug as well (arrow).
- Remove coolant hose from thermostat housing.
- Remove air ducts at lock carrier.
Vehicles with automatic transmission
- Place VAG1306 drip tray underneath engine.
- Disconnect ATF lines at lock carrier.
Vehicles with electrical coolant fan for cooling system
- Disconnect harness connector for coolant Fan Control (FC) thermal switch -F18-/F54- at lower left of radiator, and let hang free.
All models
- Unbolt intake air duct to air cleaner housing at front near lock carrier and remove.
- Disconnect harness connectors for headlight height adjustment (arrows).
- Rotate turn signal light bulb sockets counterclockwise and remove from turn signal light housing (left arrow).
- Remove coolant hose from radiator at upper coolant pipe.
- Remove hood release cable at lock carrier.
- Remove cap/dipstick from power steering fluid reservoir.
- Disconnect harness connectors at ABS hydraulic unit (arrows) and let hang free.
- Disconnect harness connector for anti-theft warning system at upper left of lock carrier and let hang free.
- Disconnect harness connectors at both horns -1- and -2- and let hang free (arrow).
CAUTION! The A/C refrigerant circuit must not be opened.
- Unbolt air guides -4- at radiator on left and right sides.
- Unbolt retaining bolts -1- and -2 from condenser.
- Disconnect harness connector -3- at A/C refrigerant low pressure switch F73-.
- Pull condenser upward out of retaining bracket, swing to side and hang at right-front wheel using wire loop.
Note: Make sure fender is protected against possible damage.
- Disconnect green harness connector (arrow) from A/C compressor magnetic clutch at lower right of lock carrier and let hang free.
- Unbolt lock carrier and safely lay aside.
- Remove engine covers.
- Remove air cleaner housing cover.
- Remove the following wiring/harness connectors:
1 - At wastegate bypass regulator valve -N75-
2 - At Evaporative Emission (EVAP) canister purge regulator valve -N80-
3 - At power output stage -N 122-
4 - At Mass Air Flow (MAF) sensor
- Uncover wiring and lay on engine.
- Pull off air duct connections and remove air cleaner housing (arrows).
- Remove coolant hoses -1- and -3-.
- Remove coolant expansion tank -2 (arrows).
- Remove wiring from Engine Coolant Level (ECL) warning switch -F66- and lay coolant expansion tank to side.
Vehicles with cruise control
- Remove actuating rod from throttle valve control module.
- Remove vacuum hose from vacuum unit.
All models
- Disconnect Accelerator Pedal (AP) cable from throttle valve control module -J338- and mounting flange (arrow) without removing positioning clip. Lay Accelerator Pedal (AP) cable aside.
- Remove air duct -1-.
- Remove hose (arrow) for Leak Detection Pump (LDP) -Vl44-.
WARNING!
- Fuel supply lines are under pressure! Before opening the system wrap a cloth around the connection. Then release pressure by carefully loosening connection.
- Fire hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Disconnect fuel supply line -1- and fuel return line -2-.
- Remove vacuum hose -3- for brake booster.
Note: For vehicles with automatic transmission, remove vacuum hose -3- from behind vacuum booster.
- Remove vacuum hose -4- to Evaporative Emission (EVAP) canister purge regulator valve -N80-.
- Remove E-box cover (arrows).
- Unclip Motronic Engine Control Module (ECM) -J220- retaining bracket.
- Remove ECM by disconnecting harness connectors -3- and -4-.
- Disconnect harness connectors -1. from Barometric Pressure (BARO) sensor -F96- and connector station -2-.
- Unhook wiring harness (arrow) and set aside.
Vehicles with automatic transmission
- Disconnect harness connector at kickdown switch (arrow).
All models
- Remove Heated Oxygen Sensor (H02S) -G39- harness connector from bracket, disconnect and set aside.
- Remove ground connection -2- and harness connector bracket -1- at plenum chamber.
- Unhook wiring harness (arrows) and set aside.
- Remove left coolant hose from heater core at lower coolant pipe on engine.
- Remove right coolant hose to heater core at cylinder head connector by detaching clip at connection flange.
- Disconnect harness connector to speedometer Vehicle Speed Sensor (VSS) -G22- at transmission and set aside.
Vehicles with manual transmission
- Disconnect harness connector to back-up light switch at transmission and set aside.
All models
CAUTION!
- Before removing ribbed belt, note direction of rotation with chalk or felt tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt. When installing the ribbed belt, make sure it is seated correctly on the pulleys.
- The A/C refrigerant circuit must not be opened.
- Loosen bolts for ribbed belt tensioner for A/C compressor (arrows), loosen ribbed belt and remove.
- Remove A/C Compressor from bracket and attach to vehicle body using wire.
- Move ribbed belt tensioner in direction of arrow to loosen ribbed belt.
- Secure belt tensioner using 3204 drift.
- Remove ribbed belt from generator pulley.
- Remove 3204 drift.
- Secure pulley for viscous clutch using M5 x 60 mm bolt.
- Remove pulley with viscous fan using 8mm hex socket wrench.
- Remove ribbed belt.
- Remove belt pulley for coolant pump. Use drift (arrow) to counterhold at belt pulley for pump.
- Remove belt.
- Remove belt pulley for power steering pump.
- Remove power steering pump and secure to side. All lines remain connected.
- Remove turbocharger to Three Way Catalytic Converter (TWC) retaining bolts.
- Remove transmission bracket for exhaust system.
Note: Flexpipe at the front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Remove wiring -1- and -2- from starter. Remove insulator from B+ connection at starter.
- Unbolt guide -4- and bracket -3- from cylinder block.
- Unbolt starter at transmission and remove.
- Unbolt Ground (GND) connection at right engine mount.
Vehicles with automatic transmission
- Using 15 mm socket Matra V1 75, remove three bolts from torque converter through opening left by removed starter. Turn crankshaft 1/3 rotation ahead for each bolt.
Note: To loosen the torque converter bolts, counterhold at the crankshaft center bolt for vibration damper.
All models
- Loosen upper nuts from left and right engine mounts several turns.
- Mark installation positions for threaded bolts -1- and centering sleeves -2- at bottom of left and right engine mounts.
Note: Different size mounting bores are prepared for the different engines available for installation.
- Remove nuts -1- from below left and right engine mounts.
- Lift engine and transmission using VAG1202A workshop crane.
WARNING! Make sure VAG1202A workshop crane is properly secured.
Note: Make sure no wires on bulkhead are damaged.
- Unbolt bolts connecting engine to transmission from below.
Vehicles With automatic transmission
- Remove ATF-line bracket on left side of engine.
All models
- Lower engine.
- Install nuts loosely on threaded mounting bolts of engine mounts.
- Remove upper nuts on engine mounts.
- Position 10-222A engine support bridge on bolted flanges of fenders with spindle facing forward.
- Attach 3147 engine support adaptor to bolt hole in transmission bellhousing.
- Connect 3147 engine support adaptor and 10-222A engine support bridge using 2024A/1 adaptor and 2024A/2 extension. Secure bolt with nut and washer.
Note: Illustration is shown with engine removed.
- Remove upper mounting bolts for engine to transmission. One bolt remains hand tight.
- Attach 2024A engine sling between engine and VAG1202A workshop crane.
WARNING!
- To properly balance the engine assembly, install the hooks in the correct hole in the rail, exactly as shown in the illustration.
- Install mounting hooks and pins on the engine sling and secure them with the positioning lock (arrows).
- Remove final mounting bolt.
Note: Check to make sure that all the hoses and connections between the engine and vehicle body have been disconnected.
- Lift engine over threaded bolts of engine mounts.
- Adjust spindle of 10-222A engine support bridge.
- Guide engine out of engine compartment from front.
Vehicles with automatic transmission
- Secure torque converter in transmission to prevent it from falling out.