Engine, Removing

Engine, Removing

Special tools, testers and auxiliary items required

• Pry lever - RMV outside mirror (80 - 200)

• Old oil collecting and extracting device (VAG 1782)

• Hose clip pliers (VAG 1921)

• Spring type clip pliers (V.A.S 5024A)

• Step ladder (VAS 5085)

• Scissor lift table (VAS 6131)

• Locking pin (T10060A)

• Tensioning strap (T10038) qty. 2

• Lifting eyebolt (3368) qty. 2

• Engine is removed downward with transmission and subframe.

• Obtain the radio antitheft code.

• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.

• Battery is located on the right side in the luggage compartment.

• Drained coolant must be stored in a clean container for disposal or reuse.

• Before raising the vehicle on the hoist (wheels off the ground), activate the vehicle lift mode.

- Remove the rubber seal for plenum chamber cover - 1 -.





- Remove the plenum chamber covers - 2 and 3 -.

- Switch on the ignition.

- Carry out the flick wipe function and let the wiper motor run to the rest position.

- Turn the ignition off and remove the ignition key.

- Pry off the cover caps - arrows - at the wiper arms using a screwdriver and remove the nuts.





- Remove the wiper arms from wiper axles.

- Remove the wind deflector - 1 - by removing the bolts - arrows - on the left and right, if present.





- Remove the dust and pollen filter, open the quick release retainers - arrows - to do so.





CAUTION!
For vehicles with Telematic, activate the service mode of Telematic control module before disconnecting the battery.

Observe procedures for disconnecting the battery.

- Remove the right luggage compartment side trim cover fastener - arrows - and cover.





- Remove the cover - 1 - above the battery.





• Disregard item - 2 -.

- Loosen the nut - arrow - and remove the ground cable from the battery.





- Remove left and right front wheels.

- Remove the noise insulation, remove items - 1 through 4 -.





- Remove the front and rear parts of the right front wheel housing liner.

- Remove the front part of the left front wheel housing liner.

- Remove the front bumper.

- Disconnect the intake air duct - 1 - from the Secondary Air Injection (AIR) pump motor (V101).





- Remove engine covers - 1 and 2 - upward.





CAUTION!
Cover the coolant expansion tank with a cloth when opening the cap to prevent getting burned by steam and/or hot coolant.

- Remove the coolant expansion tank cap.

- Remove the clips - 1 - using the (80-200).





- Remove the bolt - 2 - and remove the cover.

• Note the clips - arrows - when installing.

- Remove the hose - 1 -.





- Disconnect the hose - 1 -.





- Unclip the hose - 2 -.

- Remove the air intake tube - arrows -.

- Disconnect the electrical connector - 1 - from the Mass Air Flow (MAF) sensor.





- Remove the air filter box screws - arrows - and box.

- Remove the right headlamp.

- Press the locking mechanisms - arrows - and remove the air guide from the lock carrier at the right front.





- Remove the bolts - arrows - and remove the air guide.





- Pull the lock carrier toward the front.

- Unclip the cable clips - arrows -.





- Remove the bolts - 1 - for the torque support.

- Remove the torque support bolt - arrow - from the torque support valve (N382) and remove.





- Disconnect the electrical connector - 1 - (black) for the Heated Oxygen Sensor (HO2S) before catalytic converter.





- Disconnect the electrical connector - 2 - (brown) for the Oxygen Sensor (O2S) behind catalytic converter.

- Disconnect the electrical connector - 3 - from the solenoid valve and lay the wiring harness to the engine aside.

- Disconnect the hose - 4 - from the solenoid valve and lay the hose aside.

- Expose the electrical wires for the oxygen sensors.

- Disconnect the fuel supply line - 1 -.





- Disconnect the fuel return line - 2 -.

- Remove the right trim for the A-pillar.

- Fold the floor covering back.

- Remove the protective cover from above the main fuse holder.

- open the cover - 2 -.





- Remove the nut - 4 -.

- Remove the terminal 30 wire to the starter.

• Ignore - 1 and 3 -.

- Unfasten the harness clamp - 1 - in the right front wheel housing.





- Pull the wiring harness out from the interior - arrow -.

- Disconnect the electrical connectors - 1 and 3 -.





- Remove the ground strap bolt - 2 - from the longitudinal member.

- Remove the bracket bolts - arrows - for the wiring harness on the longitudinal member and lay the wiring harness aside.

- Place the (VAS 6208) under the engine.

- Disconnect the coolant hose - 1 - to drain the cooling system.





- Disconnect the coolant hose - 2 -.

- Open the drain plug - 3 - and drain the coolant from the oil filter bracket.

- Open the drain plug - arrow - and drain the coolant from the engine.





- Disconnect the coolant hoses - 1 and 2 -.





• Before removing the ribbed belt, mark the running direction with chalk or a felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.

• Note the previously marked direction of belt rotation and be sure that it is seated correctly on the pulleys.

- To loosen the ribbed belt, turn the tensioner clockwise in the - direction of the arrow - using a box wrench until two holes are aligned; counter hold in position using the (T10060A).





- Remove the ribbed belt.

- Disconnect the vacuum hose - 1 - to the variable tract intake manifold.





• For the sake of illustration, the Air Conditioning (A/C) compressor is shown removed.

- Disconnect the electrical connector - 1 - from the A/C compressor and free up the electrical wire.





- Remove the A/C compressor bolts - arrows - and support at the side.

• Lines remain connected.

• Lines must not be bent.

• Pay attention to the centering sleeves for guiding the A/C compressor at the retainer.

- Place the (VAS 6208) underneath the vehicle to collect any leaking hydraulic fluid.

- Loosen the clamp - 4 -, remove the suction hose - 3 - and lay aside.





- Remove the banjo bolt - 2 - for the pressure line - 1 - and lay the line aside.

- Seal the connections for the power steering pump using sealing plugs.

- Disconnect the supply and return lines - arrows - from the heater core.





- Remove the hose clamp - arrow - from the coolant pipe.





- Remove the insulation mat retainers - arrows - from the tower brace.





- Remove the tower brace bolts - 1 through 4 -.





• Note the spacer sleeves for item - 2 -.

- Remove the Engine Control Module (ECM) bolts - arrows - and lay the module aside.





• The antitheft device is not removed, the ECM remains connected.

- Disconnect electrical connector - 1 -.





- Release the E-box cover latches - arrows -.

- Disconnect the electrical connectors - arrows - and free up the wiring harness with the control module up to engine.





- Disconnect the hose - arrow - for the AIR.





- Disconnect the hose - arrow - to brake booster.





- Disconnect the hose - 1 - for the permanent ventilation from coolant expansion tank.





- Disconnect the ventilation hose - 2 - from the coolant expansion tank.

- Remove the coolant expansion tank bolts - arrows -.

- Disconnect the electrical connector for coolant level indicator.

- Remove the coolant hose from the bottom of the expansion tank.

• Wheel bearing housing must be supported to prevent upper control arm joints from being damaged.

• Observe that the threads of the (3368) does not protrude too far toward top.

- Position the (3368) into the hole at the strut dome and secure with washer - 1 - and nut - 2 -.





- Tie up the wheel bearing housing using the (T10038) as shown in the illustration.

- Have a second mechanic press the brake pedal.





CAUTION!
To loosen the bolt for the drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).

- Remove the drive axle bolt - 2 - from the left and right drive axles - 1 -.

- Remove the stabilizer bar bracket bolts - arrows - uniformly from the left and right sides.





- Remove the stabilizer bar.

- Remove the crossmember fasteners - arrows - for the noise insulation at the subframe.





- Disconnect the electrical connector - 2 - from the left level control system sensor.





- Remove the coupling rod - 1 - from the left and right track control arms.

- Remove the air spring damper bolt - arrow - from the track control arm.





- Remove the guide link nut - 1 - and track control arm nut - 2 - from the subframe.





- Pivot the guide link - 1 - and track control arm - 2 - outward.





CAUTION!
Guide link and track control arm must not hang free. Tie up both to the wheel bearing housing - arrows - as shown in the illustration.

- Repeat the above steps on the opposite side of the vehicle.

- Remove the drive axle shield bolts - arrows - and shield.





• The left shield consists of 2 parts.

- Remove the drive axle from the transmission flange.

CAUTION!
Do not damage the brake hose!

- Pivot the wheel bearing housing outward and remove the drive axle.

- Repeat the above steps on the opposite side of the vehicle.

- Loosen the double clamps - 1 and 2 - and slide them toward the front.





- Remove the front crossmember bolts - arrows - and crossmember.

- Remove the driveshaft heat shield bolts - A - and shield - arrows -.





- Remove the driveshaft bolts from the transmission flange.

- Push the driveshaft together with rear final drive. The Constant Velocity (CV) joints can move axially.

- Tie up the driveshaft to the side at the body.

- Pry off selector lever cable - 2 - from ball head using the (80-200).





- Remove the securing clip from the bracket - 1 - and free up the selector lever cable.

Prepare the Scissor Lift Table:





- Equip the (VAS 6131) with the (VAS 6131/10) and the (VAS 6131/11) as follows:





- Install the attachments on the (VAS 6131) by hand first.

- Place the (VAS 6131) in a horizontal position.

• Note the bubble level (sight glass) on the (VAS 6131).

- Push the (VAS 6131) under the engine/transmission subassembly.

- Place the attachments from the (VAS 6131/11) and the (VAS 6131/10) to the front of the engine, as shown in the illustration.





- Make sure the threaded spindles are installed completely.

- Position the attachments of the (VAS 6131/10) on the left and right to the engine carrier and subframe, as shown in the illustration.





- Place the attachments of the (VAS 6131/11) and the (VAS 6131/10) to the rear of the transmission, as shown in the illustration.





- Twist all spindles of the support elements upward far enough until all support pins make contact at the support points.

- When all attachments are positioned, lift the (VAS 6131) far enough until the engine and transmission mounts are free of tension.

- Tighten the base plates for the attachments to 20 Nm on the (VAS 6131).

- Remove the bolts tunnel crossmember bolts - arrows - and crossmember.





- Mark the installed position of the subframe on the longitudinal member using a felt tip pen.





- Remove the bolts - 1 and 4 -.

- Remove the bolts - 2 and 3 - in a diagonal sequence and in stages.

• Verify that all hoses and lines between the 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 the engine/transmission subassembly downward.

- Remove the (VAS 6131) from under the vehicle.