Engine, Removing
Engine, removing
Notes:
^ All cable ties unfastened or cut when removing engine are to be re-attached in same position during installation.
^ Engine must be removed without transmission from front of vehicle.
^ Catch drained-off coolant in a clean container for re-use or disposal.
Vehicles with automatic transmission:
^ Move selector lever to position N.
All models:
^ Obtain radio anti-theft code for vehicles with encoded radio.
^ Remove rubber seal from plenum chamber cover in direction of arrow.
^ Pull plenum chamber cover -1- toward front and remove.
^ With ignition switched off, disconnect battery Ground strap -arrow-.
^ Use screwdriver to pry off caps -3- from wiper arms.
^ Loosen hex nuts -4- by a few turns.
^ Tilt wiper arm -2- slightly to remove it from wiper shaft.
^ Remove hex nuts completely and remove wiper arms.
^ Pull off securing clips -1- and remove panel trim.
WARNING: Hot steam can escape when cap on expansion tank is opened. Cover cap with cloth and open carefully.
^ Remove engine cover -arrows-.
^ Remove air cleaner cover -arrow-.
^ Remove bolts -arrows-.
^ Disengage activated charcoal filter system solenoid valve -N80 -1- from air duct -2-.
^ Remove both screws -arrows- for air duct -2-.
^ Remove front bumper:
Vehicles with auxiliary heater:
^ Remove bolts -arrows- securing exhaust pipe of auxiliary/additional heater to noise insulation.
^ Remove noise insulation -arrows-.
^ Unbolt noise insulation holder.
^ Remove air duct in front of charge air cooler -arrows-.
^ Place drip tray VAG 1306 under engine.
^ Pull retaining clip -1- for coolant temperature sender -G2 -2- off bottom coolant hose and drain off coolant from radiator.
^ Remove bottom coolant hose from radiator.
^ Also disconnect coolant hose from oil cooler -arrow- and drain off remaining coolant.
^ Remove air hose -arrow- to charge air cooler at bottom left of lock carrier.
^ Remove lower air hose -arrows- between turbocharger and lock carrier.
^ Use 3093 to clamp off inlet and outlet pipe of cooling coil for power steering hydraulic fluid.
^ Place suitable container under hoses.
^ Disconnect hoses from cooling coil.
^ Remove air ducts on left and right of radiator -arrows-.
^ Disconnect connector -1- from air conditioner pressure switch -F129-.
^ Disconnect connector -2- from ambient temperature sensor.
^ Move both wires clear.
CAUTION: Air conditioner refrigerant circuit must not be opened.
^ Unbolt condenser -arrows- from radiator.
Note: To prevent damage to condenser and refrigerant lines/hoses ensure that lines and hoses are not stretched, kinked or bent.
^ Carefully swivel condenser downward and set down.
^ Remove impact absorber bolts on left and right -arrows-.
^ Remove hood lock cable from lock carrier:
^ Remove top coolant hose from radiator -1-.
^ Disconnect connectors -2- for left and right airbag sensor.
^ Unbolt lock carrier on left and right -arrows-.
Notes:
^ A second mechanic is needed to remove lock carrier.
^ Place lock carrier in secure position.
^ Remove lock carrier.
Vehicles with automatic transmission:
Note: Observe rules for cleanliness when working on automatic transmission:
^ Place drip tray underneath.
^ Disconnect ATF lines -arrows-.
^ Unbolt bracket for ATF lines on left of engine.
WARNING: Fuel system is pressurized. Wrap cloth around joint before opening system. Then allow pressure to escape by carefully unfastening joint.
^ Disconnect fuel supply line.
^ Seal off line so that no dirt can enter fuel system.
^ Unbolt Ground connection from plenum chamber.
^ Remove vacuum line to brake servo from plenum chamber.
^ Disconnect wires / unplug connectors from:
1- ACE valve
2- air mass meter
3- Wastegate bypass regulator valve -N75
^ Disconnect hoses 47.
^ Disconnect hose to secondary air motor -8-.
^ Move wires clear.
^ Unbolt air cleaner housing -9-.
^ Remove air cleaner.
Note: Vacuum pipe to secondary air combination valve is clipped to underside of air intake hose.
^ Remove both coolant hoses from coolant expansion tank.
^ Unbolt coolant expansion tank.
^ Lift coolant expansion tank slightly at bolt side and pull it out of catch on plenum chamber side.
^ Unbolt cover of electronics box in plenum chamber.
^ Carefully pry off retainer bar with screwdriver -arrow-.
^ Release catches -arrows- and unplug control module connectors -1and -2-.
^ Disconnect connectors 1...4 from connector rail.
^ Unbolt wire connector -5-.
^ Release catch -1- and lift off control module support.
^ Release catch -2- and pull auxiliary relay carrier in electronics box upward to remove.
^ Disengage wiring harness from electronics box housing and plenum chamber, and place on engine.
^ Remove connectors 1...4 from mount.
^ Unplug connectors.
^ Open cable ties and place wires to electrical engine components to one side.
^ Pull out retainers for both coolant hoses to heat exchanger at rear of engine.
^ Disconnect coolant hoses between engine and heat exchanger.
^ Disconnect connector -arrow- from Secondary Air Injection (AIR) pump motor -V101- and move wire clear.
^ Disconnect hose -arrow- from pipe to secondary air combination valve.
^ Remove wires -1- and -2- from starter, remove insulator from positive connection on starter.
^ Remove clamp from starter holder -4-.
^ Unbolt mount from cylinder block -3- and starter.
^ Unbolt starter from transmission and remove.
^ Unbolt Ground wire from right engine support.
^ Guide tube for positive wire to starter is attached using bolt securing engine to transmission.
Vehicles with automatic transmission:
^ Remove 3 torque converter bolts through opening of removed starter using Matra V175 15 mm A/F socket attachment (rotate crankshaft by 1/3 turn each time).
Note: When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper.
All models:
^ Separate exhaust system at clamp.
^ Remove bolts -arrows- securing catalytic converter to front exhaust pipe.
^ Unbolt transmission bracket for exhaust system -arrow-.
Note: To avoid damage, do not bend decoupling element of front exhaust pipe by more than 10°.
^ Unplug both connectors -arrows- from transmission.
^ Swivel tensioner in direction of arrow to slacken off ribbed belt.
^ Remove ribbed belt from generator pulley.
^ Unplug magnetic clutch connector from air conditioner compressor.
^ Unplug oil level gauge connector from oil pan.
CAUTION: Air conditioner refrigerant circuit must not be opened.
^ Unbolt air conditioner compressor from bracket.
^ Hang air conditioner compressor together with condenser and connected wires at right of vehicle.
^ Use hose clamp 3093 to clamp off hose between expansion tank and power steering vane pump.
^ Place drip tray underneath.
^ Disconnect ATF lines -arrows- from power steering vane pump.
Note: Differing mounting holes are provided for different engine versions.
^ Mark positions of bolted connections -1- and locating sleeves -2- on bottom right and left engine mounts.
^ Remove bottom nuts -1- on left and right engine mounts.
Note: Illustration shows vehicle with engine removed.
^ Place support bar 10-222 A behind gas-filled strut on suspension strut domes. Spindle at front.
^ Engage transmission support 3147 in bolt hole of transmission bell housing.
^ Attach transmission support 3147 to support bar 10-222 A.
^ Use support bar 10-222 A to lift engine/transmission assembly until engine mount bolts are positioned approximately 1 cm above engine supports.
^ Remove engine/transmission connecting bolts accessible from below.
^ Remove upper engine/transmission securing bolts. Leave one bolt hand-tight in place.
^ Attach lifting tackle 2024 A to engine and hook onto workshop crane 1 202 A.
Note: To balance center of gravity of assembly, position hole rails of hook attachments as shown in illustration.
WARNING: Hook attachments and locating pins on lifting tackle must be secured with locking pins -arrows in illustration.
^ Remove last securing bolt.
Note: Check that all hoses and other connections between engine and body have been removed.
^ Lift engine over studs of engine mounts.
^ Loosen support bar 10-222 A slightly.
Vehicles with automatic transmission:
^ Separate transmission from engine and at the same time remove torque converter from drive plate.
All models:
^ Pull engine away from transmission and lift engine toward front of vehicle out of engine compartment.
Vehicles with automatic transmission:
^ If necessary, secure torque converter in transmission with wire to prevent it falling out.