Engine, Removing
Engine, removing
^ Remove lock carrier; Refer to Body and Frame; Radiator Support, Service and Repair
- Detach rear engine cover (arrows).
- Detach front engine cover (arrows -1- and -2-).
- Remove coolant hoses -1 -and -3-.
- Unscrew coolant expansion tank screws -2- (arrows).
- Disconnect wire to Engine Coolant Level (ECL) Warning Switch -F66-at bottom of expansion tank.
- Disconnect vacuum hoses at locations marked by (arrows).
- Disconnect coolant hose from Y-piece (arrow).
- Disconnect vacuum hose (arrow) at intake manifold.
- Disconnect coolant hose from heat exchanger at coolant pipe on back of engine.
- Disconnect connector (arrow) to brake system vacuum pump -V1 92-.
- Set wire aside.
Note: Use pry lever 80-200 to pull out clips.
- Extract power steering hydraulic fluid from reservoir using VAG 1358 A.
Note: Place cloth under disconnection point to catch hydraulic fluid emerging.
- Remove hose -1- at power steering reservoir.
Note: Ignore item -2-.
- Disconnect coolant hoses at locations marked with (arrows).
- Disconnect coolant hose to oil cooler (arrow).
- Disconnect coolant hoses at locations marked with (arrows).
- Disconnect connector -1- at secondary air injection (AIR) pump motor V101- and set wire aside.
- Unscrew ground (GND) wire bolt -2- at longitudinal member.
- Disconnect connectors -1- and -2- in front of air cleaner housing.
- Disconnect connector -3- at evaporative emission (EVAP) canister purge regulator valve 1 -N80- item -2-.
- Detach solenoid valve from holder.
- Disconnect connector -4- at mass air flow sensor.
- Turn hose -1- to secondary air pump counter-clockwise and detach.
- Detach air hose -5- at mass air flow sensor.
- Remove bolt (arrow).
- Take out air cleaner housing with air mass meter.
- Detach air hose from throttle valve control module (arrow).
CAUTION: Fuel system is pressurized. Wrap cloth around joint before opening system. Then release pressure by carefully unfastening joint.
- Disconnect fuel supply line -1- and fuel return line -2-.
- Disconnect air hose (arrow) to secondary air system combination valves.
- Take connectors -1- to -4- out of holder on right of bulkhead.
- Set wiring harness aside.
- Unscrew nut -1- and detach strip fuse at pole shoe of positive wire.
- See Caution for disconnecting Telematics battery
- Disconnect positive wire -2- at battery positive terminal.
- Pull out positive wire to front through bulkhead.
- Set wiring harness aside.
- Disconnect connector -3- at brake booster pressure sensor -G294,
- Set wire aside.
- Remove cover for electronics box in plenum chamber (arrows).
- Use screwdriver to carefully pry off fastener (arrow) and take engine control module out of electronics box.
Note: Leave engine control module connected to wiring harness.
- Disconnect connectors (arrows) on back of connector console.
- Release catch (arrow) and lift out auxiliary relay carrier in electronics box.
- Disengage engine wiring harness at electronics box and bulkhead.
- Remove ground (GND) connections nuts -2-.
- Set wiring harness aside at holder for connectors.
- Detach holder for connectors from bulkhead -1 -.
- Set down wiring harness on engine and secure engine control module in position.
Note: Decoupling element in front exhaust pipe is never to be kinked by more than 10°, to avoid damage.
- Separate exhaust system at clamps -1- and -2-.
- Remove rear section of exhaust system.
- Remove two heat shields (arrows).
- Unscrew heat shield -A- for drive shaft (arrows).
- Screw out bolts at transmission/drive shaft flange.
- Retract drive shaft to rear final drive. Constant velocity joints are axially adjustable.
- Tie up drive shaft to body.
- Remove heat shield bolts (arrows) for transmission.
- Screw out bolt (arrow) at lug for left front exhaust pipe.
- Screw out bolts -1 -, -3- and -4- and remove heat shield with holder for exhaust system.
Note: Mark installation position of cable support bracket with respect to transmission for reinstalling.
- Remove bolt -2- for cable support bracket.
- Press ball socket off selector shaft lever (arrow).
- Remove bolts -1- and -2- for transmission mountings on left and right.
- Swivel locking lever -1- and detach transmission wiring harness connector.
- Detach connector -2- of Multi-function transmission range (TR) switch F 125- and unscrew holder bolt -3-.
- Remove heat shields for drive shafts -1- on left and right.
- Unscrew drive shaft on left and right from transmission flange.
- Tie up right drive shaft to rear.
- Remove left drive shaft.
CAUTION: Wheel bearing must not be subject to load when loosening collared bolt for drive shaft (vehicle must not be standing on its wheels).
- Remove bolts -1 -and -2-.
- Detach refrigerant lines from air conditioner compressor.
- Remove clamp (arrow) for refrigerant line.
- Remove bolt (arrow) and detach refrigerant line.
Note: Place cloth under hydraulic pressure lines to catch hydraulic fluid which escapes.
- Disconnect hydraulic pressure line (arrow) for power steering.
- Unscrew hydraulic pressure line bolt (arrow) at power steering pump.
- Unscrew nuts -1- to -4- for stabilizer bar mount on left and right.
Note:
^ When working on automatic transmission, note rules for cleanliness:
^ Place cloth under ATF lines to catch ATF which escapes.
- Remove bolt (arrow) and detach ATF lines from transmission.
- Detach ATF line (arrow) at ATF auxiliary cooler.
- Unfasten bolted joints -1- and -2- at holder for ATF lines and detach holder.
- Take out short ATF line to rear toward wheel housing and long ATF line to front.
- Unscrew nuts -1- at bottom of engine mounts on left and right.
- Loosen nut at top of left engine mount by several turns.
- Engine/transmission assembly must be raised at rear for removal. Slide mobile jack -1- from front under transmission as shown.
Note: Illustration shows position of mobile jack and shop crane with engine4ransmission assembly already removed.
Note: Never raise transmission at transmission oil pan.
- Place suitable wooden block on mount of mobile jack and position behind ATF pan at location marked by (arrow) on transmission housing.
- Raise transmission slightly with mobile jack.
- Attach plate 2024 A/2 as shown to left rear engine lifting eye. To do so, screw out bolt at plate and replace with bolt M10 x 15 mm with packing plate.
Note: To stop tight engine lifting eye and shackle from pressing against fuel rail when fitting engine, a suitable packing must be used (e.g. nuts, washers ...) to fill gap between engine lifting eye and shackle.
- Attach shackle 10-222 A12 to right rear engine lifting eye.
- When doing so, fill gap between shackle 10-222 A12 and engine lifting eye with packing -1- as shown.
- Engage lifting tackle 3033 at shackle 10-222 Al2/plate 2024 A/2 and shop crane VAS 6100 as shown.
- Carefully lift engine until pins of engine mounts are free.
- Raise mobile jack slightly.
Note:
^ Check whether all hose and line connections between engine4ransmission and body have been detached.
^ Take care not to squash lines on back of engine against bulkhead when lifting engine.
- Pull engine/transmission assembly slightly forward.
- Lift engine/transmission assembly further and pull it to front out of engine compartment.