Engine, Removing
Engine, removing
Note:
^ 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 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.
See Caution before beginning repairs on electrical system
- 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 EVAP canister purge regulator 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 sound insulation.
- Remove sound insulation (arrows).
- Unbolt sound insulation holder.
- Remove air duct in front of charge air cooler (arrows).
- Place drip tray VAG 1306 under engine.
- Pull retaining clip -1- for Engine Coolant Temperature (ECT) sensor -G2- -2- off lower coolant hose and drain coolant from radiator.
- Remove lower coolant hose from radiator.
- Disconnect coolant hose from oil cooler (arrow) and drain 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 A/C 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).
Note:
^ A second technician is required to remove the lock carrier.
^ Place lock carrier in a secure position.
- Remove lock carrier.
Vehicles with automatic transmission
Note: Observe the rules for cleanliness when working on an automatic transmission:
- Place drip tray underneath.
- Disconnect ATF lines (arrows).
- Unbolt bracket for ATF lines on left of engine.
Vehicles up to 06.03
WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- Disconnect fuel supply line -1- and set aside.
Note: Disregard -item 2-.
Vehicles as of 07.03
WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1- and -3- and unscrew union nut -2-.
All
- Seal off line so that no dirt will get into fuel system.
WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- 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- EVAP canister purge regulator valve
2- Mass air flow sensor
3- Wastegate bypass regulator valve -N75-
- Disconnect hoses 4...7.
- Disconnect hose to secondary air injection pump 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 disconnect control module connectors -1- and -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.
- Disconnect 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 (GND) 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 the crankshaft by applying a wrench to the central bolt on the 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°.
- Disconnect both connectors (arrows) from transmission.
- Swivel tensioner in direction of arrow to loosen ribbed belt.
- Remove ribbed belt from generator pulley.
- Disconnect compressor clutch connector from air conditioning compressor.
- Disconnect oil level gauge connector from oil pan.
CAUTION: Air conditioner refrigerant circuit must not be opened.
- Unbolt air conditioning compressor from bracket.
- Hang air conditioning 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 pump.
- Place drip tray underneath.
- Disconnect ATF lines (arrows) from power steering pump.
Note: Differing mounting holes are provided for different engine versions.
- Mark positions of bolted connections -1- and locating sleeves -2- on lower right and left engine mounts.
- Remove lower 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 1202 A.
Note: To balance the center of gravity of the assembly, position hole rails of hook attachments as shown in the 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 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 from falling out.