Engine, Removing
Engine, Removing
• The engine is removed downward with transmission and subframe.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
Special tools, testers and auxiliary items required
• Ball Joint Puller (T40043)
• Hose Clamps Up to 25 mm Dia. (3094)
• Drip Tray for workshop crane (VAS 6208) or (V.A.G 1306)
• Hose Clamp Pliers (V.A.G 1921)
• Ball Joint Puller (T40042)
• Scissor Type Assembly Platform (VAS 6131 A) with Support Set (VAS 6131/10)
• Hose Clamps Up to 40 mm Dia. (3093)
Removing
Before removing the engine, secure the vehicle against tipping over. For this the luggage compartment must be empty.
Observe safety precautions when disconnecting the battery.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
- Remove luggage compartment floor trim.
- Disconnect Ground (GND) cable - arrow - at battery.
- Remove the front engine cover - arrow 1 and arrows 2 -.
- Pull rear engine cover off - arrows -.
Cover the cap of the expansion tank with rag and open carefully, as hot steam for example, hot coolant may escape when opening.
- Open cap of the coolant expansion tank.
- Remove both front wheels.
• Secure brake discs using wheel bolts.
- Loosen quick-release fasteners - 1 and 2 - and remove noise insulation.
- Place (VAS 6208) under the engine.
- Remove the drain plug - arrow - on the coolant thermostat housing and drain coolant from the engine.
- Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
- Remove the bumper.
- Remove the lock carrier.
- Disconnect connector - arrow - from Secondary Air Injection (AIR) pump and free up the wiring.
- Separate coolant hose for permanent ventilation - 1 -.
- Separate the hose - 2 - for variable intake manifold.
- Disconnect hose - 3 - to Secondary Air Injection (AIR) pump.
- Disconnect the Air Conditioning (A/C) line - 1 -.
- Disconnect the coolant hose - 2 - from thermostat housing.
- Disconnect the coolant hose - 1 - for permanent ventilation from the expansion tank.
- Disconnect the hose - 2 - from the coolant pipe.
- Remove coolant expansion tank - 3 -.
- Disconnect electrical connection at Engine Coolant Level (ECL) warning switch (F66) at bottom of coolant expansion tank.
- Clamp off the oil line of the power steering fluid reservoir with (3093).
- Disconnect hose for power steering - arrow -.
- Unclip the fuel hose - 1 -.
- Separate electrical connector - 2 - from the Mass Airflow (MAF) sensor.
- Disconnect MAF sensor from the intake air duct - 3 -.
- Remove upper section of the air filter housing with the MAF sensor - arrows -.
- Separate hose - 1 - for the AIR system.
- Separate electrical connector - 2 - from air door positioner (V63).
- Remove the pin from the spreader clip - 3 - and remove the lower section of the air filter housing.
- Pull resonator - 1 - in direction of - arrow - upward and unclip it.
Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
Fuel system is under pressure! Before opening the low pressure section of the fuel injection system, wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.
- Disconnect the fuel line - arrow -.
- Disconnect the vacuum hose - 1 - for brake booster at bulkhead.
- Remove intake hose - 2 -, thereby loosening clamp - 3 -.
- Disconnect vacuum hose - 1 - to EVAP canister.
- Remove Ground (GND) wire - 2 - on the right strut tower.
- Remove nuts - 1 and 2 - and remove the right bracket for the harness connectors from bulkhead.
- Remove the GND wire - 1 - on the left strut tower.
- Remove nuts - 2 and 3 - and remove the left bracket for harness connectors from bulkhead.
- Remove rubber seal - 1 - for the plenum chamber cover.
- Remove plenum chamber cover - 2 -.
- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.
- Pull off and remove wiper arms from wiper axles.
- Remove the bolts - arrows - for cowl grill - 1 -.
- Pull the cowl grill off from the windshield.
- Remove the bolts - arrows - and remove the cover from the E-box at left in the engine compartment.
- Release the retaining tabs and pull the fuse holder - 1 - and the 3-socket relay carrier - 4 - upward and off.
- Disconnect the electrical wire connection - 3 -.
- Disconnect all electrical connections - 2 - at the rear on the connector strip.
- Disengage and free up the engine wiring harness at E-Box.
- Remove the bolts - arrows - and remove the cover for the E-box at the right in the engine compartment.
The heater pump valve unit (on the left in front of the E-box) becomes very hot during operation and could cause burns.
- Carefully pry off the retaining clip - 1 - with a screwdriver - arrows - and remove the ECM from the E-box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Unbolt electrical wiring connections - 2 and 3 -.
- Disconnect the electrical connection - 4 - at rear on the connector strip.
- Unclip smoothing capacitor - 5 - from bracket in E-box.
- Disconnect electrical connector - 6 -.
- Unclip relay carrier from E-box.
- Free electrical wiring up to generator.
- Set both wiring harnesses on engine and secure the ECM against falling down.
- Remove GND wire - arrow - on the left strut tower.
- Disconnect the coolant hose - arrow - to heater core on the rear of the engine.
- Loosen the clamping sleeves - 1 and 2 -.
- Unbolt front transverse beam bolts - arrows - and beam.
- Remove the heat shield - A - for driveshaft - arrows -.
- Remove bolts at the transmission/driveshaft flange.
- Push the driveshaft together with rear final drive. The Constant Velocity (CV) joints can move axially.
- Tie driveshaft up to the side and against the heat shield - arrow -.
- Remove the heat shield for the left drive axle - arrows -.
- Remove the left and right drive axles from the transmission.
- Have a second technician press the brake pedal.
To loosen the collar bolt for the drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove the collar bolt - 2 - at the left and right drive axles - 1 -.
- Remove the bolts - arrows - uniformly at the left and right.
- Remove the stabilizer.
- Disconnect electrical harness connector - 2 - at level control system sensor.
- Disconnect connecting link - 1 - at control arm.
- Remove suspension strut from control arm - arrow -.
- Loosen the guide link ball joint nut so far, until it is flush with the end of the thread.
• Make sure that the ball joint protective boot does not become damaged when pressing off.
• Make sure that both lever arms of the ball joint puller are positioned parallel to one another while increasing force.
• Secure ball joint puller from falling down.
- Using (T40043) press the guide link ball joint off from the tapered seat.
- If necessary, counter hold the ball joint with a 6 mm Allen key.
- Remove the nut and remove the ball joint from guide.
- Loosen the ball joint nut at the control arm so far until it is flush with the end of thread.
• Make sure that the ball joint protective boot does not become damaged when pressing off.
• Make sure that both lever arms of the ball joint puller are positioned parallel to one another while increasing force.
• Secure ball joint puller from falling down.
- Using (T40042) press control arm ball joint off from tapered seat.
- If necessary, counter hold ball joint with a 6 mm Allen key.
- Remove nut and ball joint from control arm.
- Remove the guide link - 1 - and control arm - 2 - at subframe and remove them.
- Repeat work procedure on opposite side of the vehicle.
- Remove bolts - 1 - for support bracket from transmission.
- Disengage selector lever cable - arrow -.
Prepare Scissor Lift Platform:
- Equip scissor lift platform (VAS 6131 A) with support set (VAS 6131/10) and (VAS 6131/11) as follows:
- Install attachments on scissor lift platform by hand first.
- Place (VAS 6131 A) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive (VAS 6131 A) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) at front on the engine as shown in the illustration.
- Position support elements from (VAS 6131/10) at left and right on the subframe as shown in the illustration.
- Position support elements from (VAS 6131/10) at the rear on the transmission as shown in the illustration.
- Position support elements from (VAS 6131/10) at the rear on tunnel cross member, as shown in the illustration.
- Twist all spindles of support elements upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on (VAS 6131 A).
- Remove bolts - arrows - at tunnel cross member.
- Remove bolts - 1 -.
- Mark installation position of the subframe and both of the engine mount brackets to the long members using a felt-tip marker.
- Remove bolts - 2, 3 and 4 -, in diagonal sequence and in stages.
• Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
• While lowering, carefully guide the engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- Slowly lower engine/transmission subassembly downward.
- Remove (VAS 6131 A) under vehicle.