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 - RMV Outside Mirror (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)
• Lifting Eyebolt (3368)
• Drip Tray for Workshop Crane (VAS 6208)
• Tension Strap (T10038)
• Windshield Wiper Arm Tool Set (T10369)
Procedure
CAUTION!
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. Refer to => [ Before Opening High Pressure Fuel Injection System ] Before Opening High Pressure Fuel Injection System.
- Discharge refrigerant circuit.
- Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device (V.A.G 1782).
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 drive axle to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.
- Remove cover of right luggage compartment side trim - arrows -.
- Remove cover - 1 - above battery.
• Ignore - 2 -.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Pull rear engine cover off - arrows -.
- Pull front engine cover off - arrows -.
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 front section of left front wheel housing liner.
- Remove front and rear sections of right front wheel housing liner.
- Remove noise insulation by loosening fasteners - 1, 2, 4 -.
• Ignore - 3 -.
- 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.
- Remove coolant hoses - 1 and 2 - and drain coolant.
- Disconnect vacuum line - arrow -.
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 bolts - arrows -.
- Remove coolant pipe to ATF cooler from coolant hoses - 2, 3, 4 -.
• Ignore - 1 -.
- Free up secondary air injection (AIR) air guide hose - 1 - on ATF cooler bracket.
- Remove bolts - arrows -.
- Remove ATF cooler and secure it on engine carrier.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Disconnect right coolant hose - arrow - and drain coolant.
- Free up fuel line and line to EVAP canister on air guide pipe.
- Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor (G70).
- Remove vacuum line - 4 - to air guide hose from suction jet pump.
CAUTION!
Risk of violating emissions legislation.
• Do not open hose connection - 3 -!
- Lay aside air guide hose with connected crankcase ventilation hose - 3 - by loosening hose clamps - 2 and 5 -.
- Disconnect secondary air injection (AIR) air guide hose - 1 -.
- Remove coolant hose - 2 - by pulling clip out slightly.
- Remove nut - arrows - and remove right electrical connectors bracket from bulkhead.
• Ignore items - 1 to 4 -.
- Disconnect vacuum hose - 1 -.
- Remove coolant hose - 2 - from right coolant pipe.
- Remove torque support bolt - 3 -.
CAUTION!
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
- Disconnect fuel supply line - arrow - on distribution piece.
- Disconnect the electrical connector - 2 - on the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) and remove the vacuum hose - 1 -.
- Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from bracket and lay aside with hose connected.
- Remove coolant hose - arrow - and lay it aside.
• To collect escaping power steering fluid, lay a cloth under the separating point.
- Disconnect power steering hydraulic pressure line - 1 -.
- Remove coolant hose - 2 - from left lower coolant line.
• To collect escaping power steering fluid, lay a cloth under the separating point.
- Remove hydraulic hose - arrow - from bottom of hydraulic oil reservoir.
- Remove rubber seal - 1 - and remove plenum chamber covers - 2 and 3 -.
- Pry off the caps on the wiper arms using a screwdriver.
- Loosen nuts - arrows - several turns.
- Position the Puller (T10369/1) on the windshield wiper arm - 1 - as illustrated.
- Mount the pressure piece - 2 - on the wiper axle.
- Turn the screw - 3 - clockwise until the wiper arm is pulled off the wiper axle.
- Remove nuts completely and remove wiper arms.
- Remove dust and pollen filter by opening the 4 quick-release fasteners.
• Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.
- Remove the bolts at the left and right - arrows - for the cowl panel trim - 1 -.
CAUTION!
The cowl panel trim could be damaged.
• Coat the transition area between the windshield and cowl panel trim with soapy water. Remove the trim - 1 - vertically from the retainer on the windshield beginning at the edge of the windshield.
- Carefully remove the cowl panel trim from the retainer on the windshield.
- Remove strut tower brace - arrow -.
- Remove cover over engine control module (ECM) - arrows -.
- Remove bolts - arrows -.
- Remove retaining bracket and ECM from E-box plenum chamber.
• Electrical harnesses remains connected.
- Remove Air Quality Sensor (G238) by rotating approximately 90° counter-clockwise - arrow - and removing from bracket.
- Release retaining clips - 1 to 4 -.
- Fold the cover for the E-box in the plenum chamber open slightly and pull off toward the front.
- Disconnect the multi-pin harness connectors - arrows - using Spark Plug Connector Pliers (V.A.G 1922).
- Disengage wiring harness at E-Box and bulkhead.
- Lay the wiring harness aside on the engine with engine control module (ECM) connected.
- Secure ECM against falling down.
- Remove lower right A-pillar trim.
- Fold the floor covering back.
- Remove protective cover above main fuse holder.
- Fold cap - 2 - aside.
- Remove nut - 4 -.
- Remove terminal 30 wire to starter.
• Ignore items - 1 and 3 -.
- Remove harness clamp - 1 -.
• Ignore - 2 -.
- Separate the electrical connector - 2 -.
- Remove Ground (GND) cable - 1 - from longmember.
- Remove wiring harness bracket from longmember - arrows -.
- Free up wiring harness.
- Disconnect electrical harness connector - 2 - at Level Control System Sensor.
- Disconnect connecting link - 1 - from control arm.
- Repeat work procedure on opposite side of the vehicle.
- Have a second technician press the 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 -.
- Remove bolts - arrows - uniformly at left and right.
- Remove stabilizer.
- Insert left and right Lifting Eyebolt (3368) from below into hole in strut tower.
- Secure Lifting Eyebolt (3368) with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).
CAUTION!
Risk of damaging axle joints on upper control arms.
• Support wheel bearing housing.
- Tie up wheel bearing housing at left and right with Tensioning Strap (T10038) as shown in illustration.
- Remove air spring damper from control arm - arrow -.
- Remove guide control arm - 1 - and control arm - 2 - from subframe.
- Swing guide control arm - 1 - and control arm - 2 - outward.
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 -.
- Remove drive axle from transmission flanged shaft.
CAUTION!
Risk of damaging brake line.
• Carefully tilt wheel bearing housing toward outside.
- Remove drive axle.
- Repeat work procedure on opposite side of the vehicle.
- Remove front transverse beam - arrows -.
- Remove left front muffler nuts - 1 -.
• Ignore items - 2 and 3 -.
- Remove right front muffler nuts - 1 -.
• Ignore - 2 -.
CAUTION!
Risk of damaging decoupling elements in front exhaust pipe.
• Do not bend decoupling elements in front exhaust pipe more than 10°.
- Remove nuts - arrows - on front muffler retaining straps.
- Disconnect exhaust system at clamping sleeves - 1 and 2 - and remove front muffler.
- If present, remove heat shield - A - for driveshaft - arrows -.
- Remove bolts that connect driveshaft to transmission.
- Slide driveshaft back to rear final drive; CV joints can move axially.
- Tie driveshaft up and to the side against heat shield - arrow -.
- Remove bracket for noise insulation - arrows -.
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 6131/12) at left on transmission as shown in illustration.
- Position support elements from (VAS 6131/11) at right on transmission as shown in illustration.
- Position support elements from (VAS 6131/10) at rear 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 - on tunnel cross member.
- Mark installation position of subframe on longmember using a felt tip pen.
- Remove bolts - 1 and 4 -.
- Remove bolts - 2 and 3 - in diagonal sequence and in stages.
CAUTION!
Risk of damaging hose and wiring connections as well as engine compartment.
• Make sure all of the connections between the engine, transmission, subframe and body are loosened.
• 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 approximately by dimension - a -.
• Dimension - a - = 120 mm maximum.
- 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 - RMV Outside Mirror (80 - 200).
- Remove bolts - 2 and 3 - and remove selector lever cable from transmission.
- Lower engine/transmission subassembly downward.
- Push Scissor Lift Platform (VAS 6131) with engine/transmission subassembly under vehicle.