Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Old oil collecting and extracting device (V.A.G 1782)
• Hose clamp pliers (V.A.G 1921)
• Step ladder (VAS 5085)
• Scissor lift table (VAS 6131 A) with support set (VAS 6131/10) as well as supplementary set (VAS 6131/11), (VAS 6131/13)supplementary set, (VAS6131/13) and quantity. 3 tapered mounting pin (VAS 6131/10-2)
• Drip tray for workshop crane (VAS 6208)
• Pry lever - rmv outside mirror (80 - 200)
• Hose clamp pliers (VAS 6340)
• Ball joint puller (T10187)
• If engine and transmission are to be separated after removal, the supplementary set (VAS 6131/12) will also be required.
Procedure
• Remove engine downward together with transmission and subframe with lock carrier installed.
• During installation, all cable ties must be reinstalled at the same location.
• Collect drained coolant in a clean container for disposal or reuse.
- On a vehicle with air suspension, activate vehicle lift mode.
There is a risk of injury because the fuel is under very high pressure.
• Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure.
- Reduce fuel pressure in high pressure area => [ Releasing Fuel Pressure on High Pressure Side ] Service and Repair.
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
• In order to be able to rotate the driveshaft freely, place selector lever in "N" position.
- Position driver's seat as far back and high as possible by using entire seat adjustment range.
- Switch off ignition.
- Grasp under seat and release retaining clips on back side of cover - 1 - in direction of - arrow A -.
- Remove cover in direction of - arrow B - from driver's seat console.
- Pry cover - 1 - out of floor covering with pry lever - rmv outside mirror (80 - 200).
- Raise floor covering - 2 - in slightly in area of ground (GND) wire.
- Remove nut - 3 - and remove ground (GND) wire - 4 - from ground point.
- Evacuate A/C system => Refrigerant R134a - Servicing 87.
- Extract power steering fluid from reservoir with used oil collection and extraction device (V.A.G 1782).
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 coolant reservoir cap.
- Remove both front wheels.
- Remove bolts and front - 1 - and rear - 2 - noise insulation.
- Remove left and right front wheel housing liners.
- Place drip tray (VAS 6208) under engine.
- Remove coolant hose from front coolant pipe - arrow - and drain coolant.
With 2 Zone Climate Control
- Remove coolant hoses - 1 and 2 - to heat exchanger from bulkhead.
With 4 Zone Climate Control
- Remove coolant hoses - arrows - from coolant pipes and drain remaining coolant.
Continuation for All
- If present, remove vacuum hose - 1 -.
- Remove air guide pipe - arrows -.
Without Mechanical Vacuum Pump
- Disconnect brake booster vacuum line - arrow -.
- Disconnect vacuum hose - 4 - to Leak Detection Pump (LDP) (V144) by pressing release buttons.
• Ignore items - 1, 2, 3 -.
- Disconnect vacuum hose - 1 - to evaporative emission (EVAP) canister purge regulator valve (N80) by pressing release button.
- Free up vacuum hose.
Risk of injury from fuel.
• To reduce residual pressure in fuel system, lay a clean cloth around connector and carefully loosen connector.
- Disconnect fuel supply line - 2 -.
With Mechanical Vacuum Pump
- Disconnect brake booster vacuum line - arrow -.
• Ignore items - 1, 2, 3 -.
- Disconnect vacuum hose - 1 - to evaporative emission (EVAP) canister purge regulator valve (N80) by pressing release button.
- Free up vacuum hose.
- Disconnect vacuum hose - 2 - to Leak Detection Pump (LDP) (V144).
Risk of injury from fuel.
• To reduce residual pressure in fuel system, lay a clean cloth around connector and carefully loosen connector.
- Disconnect fuel supply line - 3 -.
Continuation for All
- Remove oxygen sensor connectors - 1 to 4 - from bracket on right strut tower and disconnect.
- Unclip front differential vent hose from air filter housing - arrows -.
- Remove coolant hoses - 1 and 2 - from coolant reservoir.
- Remove coolant hoses - 1 and 2 -.
- Remove coolant hose - arrow - from front coolant pipe.
• Ignore item - 1 - hose clamps (3093).
- Open cover over B+ distributor - arrow -.
- Remove positive wires:
1. To generator
2. To starter
- Free up electrical wires.
• Place a cloth under separating point to catch dripping hydraulic fluid.
- Remove hose from power steering reservoir - arrow -.
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Remove coolant lines - 2 and 3 - from A/C compressor.
• To prevent dirt and moisture from entering, seal off open lines and connections to A/C compressor with clean plugs or protective caps.
• Ignore - 1 -.
- Pry cover caps off windshield wiper arms with screwdriver.
- Loosen nuts - 1 and 3 - a few turns.
- Loosen wiper arms in succession by tilting wiper axles slightly.
- Remove nuts completely and remove wiper arms.
• If wiper arms cannot be removed in this way, use a standard puller.
- Remove rubber seal - 5 -.
- Carefully remove plenum chamber cover - 2 - from retainer on windshield.
• Ignore - 4 -.
- Remove cover for E-box, plenum chamber - arrows -.
- Disconnect electrical connectors - 1, 2, 3 - at E-box plenum chamber connector station.
- Free up electrical wiring harness.
- Remove ground (GND) connection - 2 -.
- Remove engine control module (ECM) - 1 -
- Free up electrical wiring harness to engine.
- Loosen upper control arm nut a few turns and pull joint off with ball joint puller (T10187).
- Completely remove upper control arm nut.
- Repeat procedure on opposite side of vehicle.
- Disconnect electrical connectors - arrow - at left and right on front speed sensors.
- Remove wiring harness bolts - arrows -.
- Remove brake caliper bolts - 1 -.
• Do not change brake line bent shape.
- Engage brake caliper in wheel housing with wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Repeat procedure on opposite side of vehicle.
- Disconnect lower threaded connection - 2 - at left and right on stabilizer bar.
- Remove nuts from bolts - 1 - at left and right on strut.
• Bolts - 1 - are removed later.
- Remove bolts - arrows - at driveshaft connection at rear of transfer case.
- Slide rear driveshaft toward rear final drive; constant velocity joints can move axially.
- Remove noise insulation bracket - arrows -.
Risk of damaging decoupling elements.
• Do not bend decoupling element in front exhaust pipe more than 10°.
- Disconnect exhaust system at clamping sleeves - 1 and 2 -.
- Remove exhaust system brackets - 1 and 3 - from longitudinal member.
• Ignore - 2 -.
• Observe rules of cleanliness for working on automatic transmissions.
- Place used oil collecting and extracting device (V.A.G 1782) under separating point.
- Remove bolt - arrow - and disconnect ATF lines from ATF thermostat.
- Remove selector lever cable ball head - 2 - from selector shaft lever with pry lever - rmv outside mirror (80 - 200).
- Remove securing clips - 1 - and remove selector lever cable from transmission.
• Do not bend or kink selector lever cable.
Risk of destroying transmission control module (Mechatronic) with static discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge static electricity, touch vehicle ground with hand (without gloves).
- Disconnect electrical connector on transmission by rotating twist lock counterclockwise - arrow -.
- If engine and transmission are to be separated after removing engine/transmission assembly, remove ATF line - 1 - from transmission and remove lower bolts - arrows - in engine transmission connection.
- Disconnect electrical connector - arrow - on steering gear.
Risk of distorting airbag spiral spring.
• Separate universal joint from steering gear only when front wheels are in straight ahead position.
• Secure steering wheel with adhesive tape to prevent position of steering wheel and steering gear from changing.
- Remove universal joint bolt - arrow -.
- Remove universal joint from steering gear.
- Place used oil collecting and extracting device (V.A.G 1782) under separating point.
- Disconnect left hydraulic line - arrow - to left power steering pump cooler at lock carrier.
• Ignore hose clamps (3094).
- Remove ground (GND) connection - 1 - from right longitudinal member.
Prepare Scissor Lift Platform
- Equip scissor lift table (VAS 6131 A) with support set (VAS 6131/10) and supplementary set (VAS 6131/11) and supplementary set (VAS 6131/13) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position scissor lift table (VAS 6131 A) horizontally.
• Note bubble level (sight glass) on support platform.
- Guide scissor lift table under engine/transmission assembly.
- Attach mounting elements from support set (VAS 6131/10) and supplementary set (VAS 6131/11) at front of subframe as shown in illustration.
- Ensure threaded spindles are completely installed.
- Attach mounting elements from support set (VAS 6131/10) and supplementary set (VAS 6131/13) at left and right on transmission carrier as shown in the illustration.
- Position mounting elements supplementary set (VAS 6131/13) at left and right on suspension struts as shown in the illustration.
- Attach mounting elements from supplementary set (VAS 6131/10) at left and right on subframe as shown in the illustration.
- Attach mounting elements from support set (VAS 6131/10) at left and right on transmission carrier as shown in illustration.
- Rotate mounting element spindles upward until all mounting pins come in contact with mounting points.
- Attach mounting element base plates to scissor lift table (VAS 6131 A) and tighten to 20 Nm.
- Mark position of subframe, engine carrier and transmission carrier to long members with a felt tip pen.
- Remove bolts - 1 to 4 - diagonally in stages.
- Remove bolt - 1 - at left and right.
• Ignore - 2 -.
• Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.
• To avoid damage, carefully guide engine/transmission assembly out of engine compartment when lowering.
• Carefully guide suspension struts onto long members.
- Lower engine/transmission assembly.
- Remove scissor lift table (VAS 6131 A) with engine/transmission assembly under vehicle.
- Separate the engine from the transmission. => [ Engine and Transmission, Separating ] Engine and Transmission, Separating.
- Secure the engine and transmission to the holder. => [ Engine and Transmission, Securing to Holder ] Engine and Transmission, Securing to Holder.