Engine, Removing
WARNING! The ignition must be switched OFF when:
- Disconnecting ignition wires.
- Disconnecting fuel injection system wiring.
- Connecting or disconnecting test equipment leads.
- Disconnecting battery.
- Washing the engine or engine compartment
CAUTION! BEFORE disconnecting the battery:
- Stop the engine.
- Ignition must be switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM)
- Determine correct coding for the anti-theft radio.
CAUTION! Whenever working on the fuel supply or fuel injection systems, always observe the following rules of cleanliness:
- Thoroughly clean fuel supply lines and hose connections and the surrounding area before disconnecting.
- Place removed components on a clean surface and cover. Use plastic sheeting or paper. Do not use fluffy rags that could leave lint
- Install only clean components. Do not remove replacement parts from the packaging unto immediately before installing them. Do not use parts that have been stored without packaging (for example in tool boxes) etc.)
- Avoid working with compressed air when the fuel system is open.
- Replace all tie wraps that were cut and install them in the same location from where they were removed.
Special tools and equipment:
- Drip tray V.A.G 1306
- Hose clamps 3094
- Pin wrench 3212
- Open-end wrench3312
- Drift 3204
- Engine lifting appliance V.A.G 3033
- Workshop crane V.A.G 1202A
- Engine/transmission jack V.A.G 1383
Notes:
- Remove engine together with transmission from the front.
- Obtain anti-theft code for radio.
- Replace all cable ties detached or cut when removing the engine in the same position when installing.
- The battery is located behind a cover on the right side of the luggage compartment.
- With ignition switched off, disconnect battery ground strap.
- Unscrew grille on left side, unclip on right side (arrow).
- Remove noise insulation.
- Unbolt bumper on left and right sides by removing screw(arrow).
Vehicles with headlight washers:
- Clamp off washer hose for headlight washers with clamp 3094.
- Disconnect hose to jets at bumper in right air intake grille.
- Disconnect connector for horn and fog lights and remove bumper.
- Install drain hose -1- to hose connection.
- Place drip tray V.A.G 1306 under engine.
WARNING! The cooling system is under pressure when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly.
- Drain coolant from radiator (bottom left) (arrow).
- Open drain plugs -arrows- and drain coolant.
CAUTION! Dispose of used coolant properly.
- Remove cover -1-
- Remove intake duct -2- to air cleaner.
- Clamp off hydraulic oil lines for power steering with clamps 3094.
- Disconnect hydraulic oil lines -arrows- from power steering.
- Disconnect coolant hose -1-
- Disconnect ATF line -2- at radiator (automatic transmission).
- Free connector -1- for outside temperature sensor and wiring.
- Disconnect connector for pressure switch -2-.
- Remove air shroud for radiator at right and left sides -arrows-.
CAUTION! The A/C refrigerant circuit must only be opened by specially trained technicians using proper fools and equipment
- DO NOT open air conditioning refrigerant circuit
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
- Remove coolant loop for hydraulic oil and lay aside.
- Detach but do not remove A/C condenser, hang up with wire.
- Disconnect connectors for left and right direction indicator lights.
- Disconnect connectors for left and right headlights.
- Remove coolant hose (arrow) at top right of radiator.
- Disconnect connector (arrow) for radiator fan and move wiring aside.
- Disconnect ATF line -1- for automatic transmission.
- Disconnect ATF line -2- from radiator.
- Remove coolant hose -1- from radiator.
- Disconnect connector from thermal switch -2-.
- Disconnect hood cable.
- Remove left and right hood bumpers.
- Remove bolts for air shroud under hood bumpers (arrow).
- Remove left and right bumper impact absorbers.
- Remove radiator with shroud.
- Disconnect connector -1- from oil level sensor and move wiring aside.
- Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan using wrench 3312 (left hand thread).
CAUTION! Mark the running direction of the belt with crayon or marker before removing Reinstalling a used belt in reversed running direction could damage the belt.
- When installing ribbed belt, be sure belt is seated correctly on the belt pulleys.
- To loosen ribbed belt, turn tensioner clockwise with 19 mm wrench until the two holes align. Hold tensioner in position with drift 3204.
- Remove ribbed belt.
- Remove ribbed belt pulley on power steering pump, using pin wrench 3212 to counter-hold.
Note: Install shims behind ribbed belt pulley again.
- Remove power steering pump from bracket -arrows- and place on side member.
- Remove A/C compressor -arrows- and hang up.
CAUTION! The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.
- DO NOT open air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
- Remove bracket for viscous fan -arrows-.
- Remove engine cover -arrows-.
- Remove cylinder head covers -1- and -2-.
- Remove air intake pipe -arrows between air cleaner and throttle body.
- Disconnect connector for left oxygen sensor (arrow) and move wiring aside.
- Disconnect fuel supply and return lines -1-.
- Disconnect hose -2-.
- Remove cover -1- by removing bolts -arrows-.
- Open E-box by removing 7 screws -arrows-. Remove cap for screw at upper left.
Note: When installing observe correct mounting of altitude sensor-2-.
- Remove bracket-3- at left and right strut caps.
- Disconnect connectors from Engine Control Module (ECM) -1- and Transmission Control Module (TCM) -2-. Unclip connector -3- at bulkhead .
- Disconnect connectors -4-.
- Remove holder for relay and fuses -arrows-.
- Detach sealing strip between engine compartment and plenum chamber.
- Detach wiring harness from bulkhead, remove spacer sleeves. Move wiring aside and place on engine.
- Disconnect hose for brake booster-1
- Disconnect connector -2- and move wiring aside.
- Disconnect connector-3- and remove from retainer.
- Disconnect coolant hoses -4- to and from heater core at bleeder valves.
- Disconnect coolant hose (arrow)
- Remove cover -1- by removing bolts -arrows- and releasing clip -2-.
- Remove air cleaner upper part.
- Disconnect connector for air flow sensor (arrow) and move wiring aside.
- Disconnect connector -1- for Evaporative Emission (EVAP) Purge Valve.
- Remove connector -2- for Second Air Pump and clear wiring.
- Disconnect vacuum line for intake manifold change-over valve in front of left headlight.
- Lift carpet on driver's side.
- Pull out wiring to oxygen sensor after Three Way Catalytic (TWC) Converter (arrow) and disconnect. Push wiring down through opening .
- Lift carpet on passenger's side.
- Pull out wiring to oxygen sensor after Three Way Catalytic (TWC) Converter (arrow) and disconnect. Push wiring down through opening.
- Remove right front wheel.
- Remove cover -arrows- on long member.
- Remove junction box cover.
- Cut tie wrap.
- Disconnect both connectors -1- at junction box.
- Disconnect starter cable -3- at junction box.
- Disconnect ground cable -2-.
- Detach wiring harness from long member4-.
- Remove air duct for generator.
- Unclip hose -1- from retainer and move aside.
- Remove retainer -2- by turning.
- Loosen top bolt between exhaust manifold and exhaust pipe.
- From below loosen bolts -arrows- between exhaust manifold and front exhaust pipe.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
- Remove exhaust pipe from retainer (arrow).
- Loosen double clamp -1- and push it forward. Leave double clamp -2- connected until later.
- Carefully remove exhaust pipe with catalytic converter.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10 to prevent damage.
- Loosen top bolt between exhaust manifold and exhaust pipe (accessible through opening for tie rod).
- Loosen bolts -arrows- between exhaust manifold and front exhaust pipe (from below).
- Remove right exhaust pipe from retainer (arrow).
- Loosen double clamp -2- and push it forward.
- Carefully remove exhaust pipe together with catalytic converter.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
- Mark position of drive shaft in relation to transmission output flange.
- Unbolt drive shaft.
- Support drive shaft (hang up with wire).
- Disconnect selector lever cable at bracket -right arrows-.
- Unclip retainer at bracket and move aside -left arrow-.
- Disconnect left and right drive axles.
- Remove splash shield for left drive axle.
- Lift transmission using engine/transmission jack V.A.G 1383.
- Remove left and right transmission mounts.
- Lower transmission and remove jack.
- Remove bolts for left and right engine mounts.
- Attach engine sling V.A.G 3033 at two engine lifting points shown.
- Position workshop crane V.A.G 1202A and hook up sling V.A.G 3033.
WARNING!
- To properly balance the engine assembly, install the hooks in the correct notches of the sling, exactly as shown in the illustration.
- Assure that hooks are firmly connected with the lifting eyes.
- Carefully lift engine and transmission and remove toward front.