Removal
NOTE:- All cable ties that are loosened or removed in order to remove the engine must be replaced or reinstalled in the same positions when the engine is reinstalled.
- The engine is removed from the front, together with the transmission.
CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.
1. Ignition switched off.
2. Disconnect battery ground strap.
3. Remove intake air grille.
4. Remove screw on left (arrow), unclip grill on right.
5. Remove noise insulation panel.
6. Unbolt bumper at left and right.
7. Detach hose to jets on bumper (in right side air grille).
8. Drain coolant at bottom left of radiator (arrow).
9. Remove intake air duct between air cleaner and throttle body.
10. Unbolt engine cover.
11. Remove coolant hose clamps at right-side belt guard.
12. Remove electronics box cover by removing seven bolts (arrows).
- Unclip whole cover for bolt at top left.
13. Disconnect all connectors from Engine Control Module (ECM) -1- and Transmission Control Module (TCM) -2- at bulkhead -3-.
14. Unbolt cruise control control module with relay and fuse bracket (arrows).
15. Remove sealing strip between engine compartment and plenum chamber.
16. Cut open cable ties (2 places) at engine wiring harness.
17. Remove wiring harness from plenum panel, remove spacer sleeves, expose wiring and place down on engine.
18. Disconnect vacuum line to brake booster unit.
19. Disconnect vacuum line at cruise control control module.
20. Disconnect accelerator pedal cable and expose.
21. Disconnect coolant lines to heater core (supply and return) at vent valves.
22. Disconnect Heated Oxygen Sensor (HO2S) connectors on left and right sides and push out of holder.
23. Unbolt ignition power output stage.
24. Remove top part of air cleaner.
25. Disconnect harness connector at Mass Air Flow (MAF) sensor.
26. Expose cable to engine.
27. Unbolt coolant vent line to expansion tank at radiator.
28. Remove coolant supply line at expansion tank.
29. Remove hydraulic reservoir for this step.
30. Disconnect vacuum line for intake manifold change-over valve, located at front by left headlight.
31. Unplug left and right knock sensor connectors at fuel rail.
32. Cut open cable ties (4 places).
33. Disconnect harness connectors at fuel injectors.
34. Unbolt fuel rail, carefully remove together with fuel injectors, and place down to side.
35. Cover openings to engine with clean cloths.
36. Remove bolts connecting exhaust manifold to front exhaust pipe on left and right sides (one bolt each).
37. Unbolt crossmember.
38. Loosen double clamp.
39. Remove Three Way Catalytic Converter (TWC).
40. Disconnect exhaust system at retaining loop and remove.
41. Unbolt exhaust pipes (left and right) from exhaust manifold.
42. Unbolt TWC bracket along with spring.
43. Remove TWC along with front pipe.
44. Remove heat shield above three way catalytic converter.
45. Unbolt heat shield for selector lever cable at transmission pan.
46. Unbolt selector lever cable at bracket.
47. Unclip lock at bracket and expose.
48. Unbolt left and right drive axles.
49. Unbolt left drive axle shield.
50. Disconnect starter cable connector at junction box on right side long member.
51. Unclip junction box cover.
52. Disconnect electrical con nectar
53. Unbolt starter cable in junction box and at bracket.
54. Remove generator air guide.
55. Place catch pan below lines to collect automatic transmission fluid (ATF).
56. Disconnect line to transmission oil cooler.
57. Unbolt coolant hose at bottom right of radiator.
58. Disconnect Engine Coolant Temperature (ECT) sensor above hose.
59. Unbolt torque support (note washers).
60. Unbolt radiator air guide on left and right sides.
61. Disconnect high pressure switch connector.
62. Disconnect left and right headlight connectors.
63. Remove left headlight.
64. Unclip outside temperature sensor at bottom in front of radiator, cut open cable clip, and expose cable.
65. Unbolt cooling loop for power steering fluid and place to side.
66. Detach A/C condenser and tie up to side (to relieve strain on lines and radiator).
NOTE:
- Disconnect A/C refrigerant line brackets and support points only.
- DO NOT open the air conditioning refrigerant circuit.
- Avoid damage from bending, refrigerant lines kink easily.
67. Disconnect coolant fan wiring.
68. Cut open cable ties (3 places).
69. Remove hood supports at both front fenders.
70. Remove lock carrier bolts located below hood support (note washers).
71. Unbolt impact absorbers for bumper on left and right sides.
72. Remove lock carrier along with radiator.
73. Loosen ribbed belt by pulling firmly down in middle by hand and install drift tool No. 3204, or equivalent.
74. Remove ribbed drive belt.
75. Unbolt hydraulic pump belt pulley (note washers).
76. Secure washers on shaft with bolt, if necessary.
77. Unbolt hydraulic pump from mounting bracket and place down at side member.
78. Unbolt A/C compressor, lines remains connected. Do not damage lines.
79. Secure A/C compressor to side, note centering bushings.
NOTE:
- Disconnect A/C refrigerant line brackets and support points only.
- DO NOT open the air conditioning refrigerant circuit.
80. Avoid damage from bending. Refrigerant lines kink easily.
81. Unbolt torque support with bonded rubber bushing at left front of engine.
82. Raise transmission using tool tool No. VAG 1383, or equivalent.
83. Remove right and left transmission mounts.
84. Remove left transmission support.
85. Lower and remove transmission hoist.
86. Unbolt left and right engine mounts.
87. Unhook both gas-filled struts at hood.
88. Position hood in vertical position and support with auxiliary tool.
89. Install brackets tool No. VAG 3180, or equivalent, on both rear engine lifting points.
90. Attach lifting device 3033 to both brackets evenly.
91. Slide in assembly crane tool No. VAG 1202 A (500 kg), or equivalent, and attach lifting device tool No. 3033, or equivalent.
92. Raise engine carefully and pull out toward front.