Engine, Removing
Engine, Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• Drained coolant must be stored in a clean container for disposal or reuse.
• During installation, all cable ties must be re-installed at the same location.
Special tools, testers and auxiliary items required
• Pry lever (80 - 200)
• Old oil collecting and extracting device (V.A.G 1782)
• Hose clamp pliers (V.A.G 1921)
• Spring-type clip pliers (VAS 5024 A)
• Step ladder (VAS 5085)
• Scissor Lift Table (VAS 6131) with Support Set (VAS 6131/10) and Supplementary Set (VAS 6131/11) and (VAS 6131/12)
• Drip tray for workshop crane (VAS 6208)
• Tension strap (T10038)
Work procedure
CAUTION!
Risk of vehicle tipping over with engine removed.
• Secure vehicle. Luggage compartment must be empty for this.
There is a risk of injury because the fuel is under very high pressure.
• Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.
- Reduce fuel pressure in high pressure area => [ Before Opening Fuel Injection System High Pressure Area ] Before Opening Fuel Injection System High Pressure Area.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
• In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.
- Remove luggage compartment floor trim.
- If battery is secured with a retaining strap, open strap.
- Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.
- With ignition switched off, disconnect Battery Ground (GND) wire - arrow -.
- Discharge refrigerant circuit => Refrigerant R134a - Servicing.
- Extract hydraulic oil from power steering reservoir using Used Oil Collecting and Extracting Device (V.A.G 1782).
- Pull rear engine cover- arrows - off.
- Pull front engine cover- arrows - off.
CAUTION!
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• To reduce pressure, cover coolant reservoir cap with cloth and carefully open.
- Open cap on coolant expansion tank.
- Remove both front wheels.
- Remove sound insulation by loosening securing pieces - 1, 2 and arrow -.
- Place drip tray for workshop crane (VAS 6208) under engine.
- Remove drain plug - 1 - on Map Controlled Engine Cooling Thermostat (F265) and allow coolant to drain.
• Ignore - 2 -.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Place old oil collecting and extracting device (V.A.G 1782) under engine.
• Observe the rules of cleanliness for working on automatic transmissions.
- Disconnect ATF lines - 1 and 2 - and power steering hydraulic line - 3 -.
• To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.
- Remove coolant hoses - 1 and 2 - from Map Controlled Engine Cooling Thermostat (F265).
CAUTION!
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Remove bolts - 1 and 2 -.
- Disconnect refrigerant lines from A/C compressor.
• To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.
- Remove Ground (GND) strap - arrow - from right longitudinal member.
- Disconnect electrical connector - 2 - on Secondary Air Injection (AIR) Pump Motor (V101) and free up wire.
- Remove air guide hose - 1 - and free it up.
CAUTION!
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
- Disconnect fuel line - arrow -.
- Free up fuel line and line to EVAP canister on air filter housing and air guide pipe.
- Disconnect electrical connector - 2 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) and remove vacuum hose - 1 -.
- Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from bracket and lay aside with hose and fuel line connected.
• Disregard - arrow -.
- Remove bolts - arrows -.
- Remove air duct - 1 and 2 -.
- Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor (G70).
- Remove vacuum line - 3 - to air guide pipe.
CAUTION!
Risk of violating emissions legislation.
• Do not open hose connection - 2 -!
- Lay aside air guide hose with connected crankcase ventilation hose - 2 - by loosening hose clamps - 4 - and opening clips - arrows -.
• Ignore - 5 -.
- Open clips - arrows - and remove upper part of air filter housing.
- Disconnect vacuum line - 1 -.
- Remove pin from spreader clips - 4 -.
- Remove lower part of air filter housing and on backside, disconnect electrical connection - 2 - at intake air switch-over valve (N335).
- Disconnect air guide hose - 3 - to Secondary Air Injection (AIR) pump.
- Remove coolant hose - 1 - from radiator and right coolant pipe - 2 -.
- Lay coolant hose on lock carrier.
- Disconnect vacuum hose - 1 -.
- Disconnect coolant hose - 2 -.
- Remove power steering hydraulic hose - 3 -.
- Disconnect electrical harness connector - arrow - to Brake System Vacuum Pump (V192).
- Free up electrical wiring.
• To improve clarity, the illustration is shown with headlamp removed.
- Remove coolant hose - 2 - from coolant reservoir.
- Remove coolant reservoir - arrow - and disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant reservoir.
- Lay aside coolant reservoir with connected coolant hoses - 1 and 3 -.
- Remove vacuum hoses - 1 and 2 - from T-piece on bulkhead.
- Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.
- Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
- Loosen wiper arms by tilting slightly from windshield wiper axle.
- Remove nuts completely and remove wiper arms.
• If wiper arms cannot be removed in this way, use a standard puller.
- Remove bolts - arrows - and remove cowl grille - 1 - from windshield.
- If vehicle is equipped with dome braces, remove bolts - 1 and 3 - and remove dome braces - 2 -.
- Remove bolts - arrows - and remove cover form E-box at left in engine compartment.
- Release retaining tabs and pull fuse holder - 1 - and 3-socket relay carrier - 4 - upward and off.
- Remove electrical wire connection - 3 -.
- Disconnect all electrical connections - 2 - at rear on connector strip.
- Disengage and free up engine wiring harness at E-Box.
- Disconnect electrical harness connector - arrow - at Brake Booster Pressure Sensor (G294).
- Disconnect vacuum line - arrow - to brake booster at bulkhead.
- Remove nut - 1 - and remove left electrical connectors bracket from bulkhead.
- Remove Ground (GND) wire - arrow - from left strut tower.
- Remove bolts - arrows - and remove cover for E-box at right in engine compartment.
CAUTION!
Risk of burning on heater pump valve unit (at left in front of E box).
• Wear protective gloves when working near heater pump valve unit.
- Carefully pry off retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove ECM from E-box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Unclip suppression capacitors - 5 - from bracket in E-box.
- Disconnect electrical connection - 4 - at rear on connector strip.
- Disconnect electrical wiring connections - 1 and 2 -.
- Release locking mechanisms - arrows - and remove relay carrier upward.
- Remove nuts - 3 - and remove right electrical connectors bracket from bulkhead.
- Remove nut - 1 - on positive terminal pick-off.
- Remove Ground pins - 2 -.
- Free electrical wiring up to generator using pry lever (80-200).
• If necessary, use silicon-free spray lubricant to facilitate removal of wiring clips.
- Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.
- Have a second technician press brake pedal.
CAUTION!
Risk of damaging wheel bearing.
• To loosen drive axle collar bolt, vehicle must not be resting on wheels.
- Remove collar bolt - 2 - at left and right drive axles - 1 -.
- Evenly remove left and right nuts - 1 -.
- Remove left and right bolts - 2 - and remove stabilizer bar.
- Disconnect electrical harness connector - 2 - at Level Control System Sensor.
- Disconnect connecting link - 1 - from control arm.
CAUTION!
Risk of damaging axle joints on upper control arms.
• Support wheel bearing housing.
- Tie up wheel bearing housing with Tension Strap (T10038) as shown in illustration.
- Remove suspension strut from control arm - arrow -.
- Remove guide control arm - 1 - and control arm - 2 - from subframe.
CAUTION!
Risk of damaging axle joints on guide control arm and control arm.
• Tie guide control arm and control arm up to wheel bearing housing - arrows -.
- Pivot guide control arm - 1 - and control arm - 2 - outward.
- Repeat work procedure on opposite side of vehicle.
- Remove drive axle from transmission flanged shaft.
CAUTION!
Risk of damaging brake line.
• Carefully tilt wheel bearing housing toward outside.
- Remove drive shaft.
- Repeat work procedure on opposite side of vehicle.
- Remove front transverse beam - arrows -.
- Remove left front muffler nuts - 1 -.
• Ignore - 2 and 3 -.
- Remove right front muffler nuts - 1 -.
• Ignore - 2 -.
CAUTION!
Risk of damaging decoupling elements in front muffler.
• Do not bend decoupling elements in front muffler more than 10°.
- Remove bolts - 1 and 2 -.
- Loosen left clamping sleeve - 1 -, slide back and remove left front muffler.
- Loosen right clamping sleeve - 2 -, slide back and remove right front muffler.
- Remove subframe transverse beam - arrows -.
- Remove heat shield - A - for drive axle - arrows -.
- Remove bolts that connect driveshaft to transmission.
- Slide driveshaft back to rear final drive; constant velocity joints can move axially.
- Tie driveshaft up and to the side against heat shield - arrow -.
- Remove bolts - arrows - for torque support.
• The torque support can be removed at a later time.
Vehicles with auxiliary heater:
- Remove left front wheel housing liner.
- Remove bolt - arrow - for corrugated exhaust pipe.
- Loosen nut - A - on clamp for corrugated exhaust pipe.
- Remove bolt - B - and remove muffler with corrugated exhaust pipe.
Prepare scissor lift platform:
- Equip Scissor Lift Table (VAS 6131) with Support Set (VAS 6131/10) as well as Supplementary Set (VAS 6131/11) and (VAS 6131/12) as follows:
- Install attachments on scissor lift table by hand first.
- Place scissor lift platform (VAS 6131) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive scissor lift platform (VAS 6131) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) at front on engine as shown in illustration.
- Ensure right threaded spindle at front of engine is completely installed.
- Position support elements from (VAS 6131/10) at left and right on subframe as shown in illustration.
- Position support elements from (VAS 6131/10) and (VAS 6131/12) at left on transmission and tunnel cross member as shown in illustration.
- Position support elements from (VAS 6131/10) and (VAS 6131/11) at right on transmission as shown in 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 scissor lift platform (VAS 6131).
- Remove bolts - arrows - at tunnel cross member.
- Remove bolts - 1 -.
- Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
- Remove bolts - 2, 3, 4 - in diagonal sequence and in stages.
CAUTION!
Risk of damaging hose and wiring connections as well as engine compartment.
• Check whether all are loosened between engine, transmission, subframe and body.
• Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.
- First lower engine/transmission assembly using scissor lift platform (VAS 6131) only approx. by dimension - a -.
• Dimension - a - = 100 mm maximum.
- On a vehicle with heat shield, remove bolts - arrows - and remove selector lever cable heat shield.
- Identify installation position of selector lever cable bracket with a felt-tip pen for re-installation.
- Press ball socket - 1 - of selector lever cable from selector shaft lever using pry lever (80 - 200).
- Remove mounting bracket - 2 - from transmission.
- Move selector lever cable clear.
- Remove torque support.
- Lower engine/transmission subassembly downward.
- Push scissor lift platform (VAS 6131) with engine/transmission subassembly under vehicle.