Engine, Removing
Engine, Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• Before beginning work, make sure that the support element (VAS 6131/10-12) for the scissor lift table (VAS 6131) is also readily equipped with the support set (VAS 6131/10).
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
• Drained coolant must be stored in a clean container for disposal or reuse.
Special tools, testers and auxiliary items required
• Pry Lever (80-200)
• Hose clamps up to 25 mm diameter (3094)
• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)
• Hose clamp pliers (V.A.G 1921)
• Spark plug connector pliers (V.A.G 1922)
• Step ladder (VAS 5085)
• Scissor lift table (VAS 6131) with support set (VAS 6131/10) with added support element (VAS 6131/10-12) as well as supplementary set (VAS 6131/11)
- Discharge refrigerant circuit.
- Activate vehicle lifting mode.
CAUTION!
Observe procedures for disconnecting battery.
- Switch off ignition.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
- Remove cover - arrows - of right luggage compartment side trim.
- Remove cover - 1 - above battery.
• Ignore - 2 -.
- Disconnect Ground (GND) cable - arrow - at battery.
- Carefully pull engine cover at the rear and middle upward and off - arrows 1 -.
- Then, pull the engine cover forward and off from intake manifold - arrows 2 -.
- Remove cover above coolant reservoir - arrows -.
CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
• Secure brake discs using a wheel bolts.
- Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
- Remove front and rear sections of the left and right front wheel housing liners.
- Place drip tray (V.A.G 1306) or drip tray (VAS 6208) under engine.
- Disconnect coolant hose - arrow - from left coolant pipe and drain the coolant.
- Disconnect coolant hose next to left drive axle from coolant pipe - arrow - and drain coolant.
- Disconnect coolant hoses - 1 - and - 2 - at radiator and drain the coolant.
- Disconnect coolant hoses - arrows - and drain remaining coolant.
- Disconnect electrical harness connector - arrow - from oil pressure switch (F1).
• Illustration is shown with lock carrier removed.
- Clamp off return hose - 1 - for power steering pump with hose clamp (3094).
- Disconnect return hose - 1 - from power steering pump.
• Ignore - 2 -.
- Disconnect air duct hoses - 1 - and - 2 - at the secondary air injection (AIR) pump by pressing the release buttons.
- Pull off both air duct hoses - arrows - at bottom of lower part of left air filter housing, thereby pressing the release buttons.
- Disconnect electrical connector - 3 - for Mass Air Flow (MAF) Sensor 2 (G246).
- Disconnect hose - 2 - from air duct hose.
- Disconnect air duct hose - 1 - at intake manifold.
- Remove bolts - arrows -.
- Remove upper part of left air filter housing.
- Remove air duct - 1 -.
- Remove bolts - arrows -.
- Remove lower part of left air filter housing.
- Disconnect coolant hose at position indicated by - 2 -.
- Disconnect air guide hoses - 1 - and - 3 - from combination valves.
- Pull air duct hoses upward and out from engine compartment.
• Place a rag under hydraulic line to catch escaping hydraulic fluid.
- Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of the longitudinal member.
• Ignore - 1 -.
• Do not bend or stretch lines or hoses as A/C compressor and/or refrigerant lines/hoses may be damaged.
- Disconnect refrigerant lines from A/C compressor - arrows -.
- Plug openings of the AC compressor.
- Disconnect coolant hose - 1 -.
- Disconnect vacuum hose - 2 - to brake booster.
- Disconnect vacuum hose - arrow - to Leak Detection Pump (LDP) (V144) from intake manifold.
- Disconnect electrical connector - 1 - for mass air flow (MAF) sensor (G70).
- Disconnect air duct hose - 4 - at intake manifold.
- Unhook retainer for connections - 2 - and - 3 - at upper part of air filter housing.
- Remove bolts - arrows -.
- Remove upper part of right air filter housing.
- Remove air duct - 1 -.
- Remove bolts - arrows -.
- Remove lower part of right air filter housing.
• Place a cloth under separation point to catch escaping coolant.
- Disconnect coolant hose - arrow - at right on engine.
- Remove bolts - arrows - and remove right combination valve for secondary air injection.
• Ignore - 1 -.
- Remove bolt - arrow - at torque support mount.
- Disconnect vacuum line to intake manifold - arrow -.
CAUTION!
• Note rules of cleanliness for working on the fuel injection system => [ Clean Working Conditions ] Clean Working Conditions.
• Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Mark fuel return line - 1 - and fuel supply line - 2 -.
- Disconnect electrical connectors - 1 - and - 3 -.
- Free up electrical wiring.
- Remove vacuum hoses - 2 - and - 4 - at the EVAP canister purge regulator valve (N80) and at the EVAP canister purge regulator valve 2 (N333).
- Free up vacuum hoses.
- Disconnect electrical connection - 6 - at throttle valve control module (J338).
- Disconnect vacuum hose - 1 -.
- Pull off hoses - 4 - and - 5 - for the crankcase breather.
- Remove bolts - 2 - and - 3 -.
- Remove right intake manifold side-part.
- Remove rubber seal - 1 - for plenum chamber covers.
- Remove plenum chamber covers - 2 - and - 3 -.
- Pry off caps on wiper arms using a screwdriver.
- Loosen nuts - arrows - by several turns.
- Loosen wiper arms by gently rocking the wiper arm. Remove nuts 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 bolts - arrows - at left and right for cowl grill - 1 -.
- Carefully pull the cowl grill off from the retainers at the windshield.
- Remove strut tower brace - arrow -.
- Remove bolts - 1 - and - 2 - and remove retaining bracket.
- Release retaining tabs - arrows - and remove both engine control modules (ECM).
• Electrical harnesses remains connected.
- Turn sensor for air quality (G238) approximately 90° counter-clockwise - arrow - and remove from retainer.
- Release retaining clips - 1 to 4 -.
- Fold cover for the E-box in the plenum chamber open slightly and pull off toward the front.
- Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers (V.A.G 1922).
- Disengage engine wiring harness at E-Box and at bulkhead.
- Lay the wiring harness aside on the engine with engine control modules (ECM) connected.
• Protect the engine control modules from falling off.
- Pull coolant hose off from bulkhead - arrow -.
- Remove right A-pillar trim.
- Fold floor covering back.
- Remove protective cover above main fuse holder.
- Fold cap - 2 - aside.
- Remove nut - 4 -.
- Remove terminal 30 wire to starter.
• Ignore - 1 - and - 3 -.
- Remove harness clamp - 1 - in right front wheel housing.
- Pull wiring harness out from interior - arrow -.
- Disconnect electrical connectors - 1 - and - 3 -.
- Remove Ground (GND) cable - 2 - on longmember.
- Remove bracket for wiring harness at longmember - arrows - and free up wiring harness.
- Loosen clamping sleeves - 1 - and - 2 -.
- Remove nuts - arrows - at retaining tabs for left and right front mufflers.
• Do not bend the decoupling elements at the front mufflers more than 10° or they could be damaged.
- Remove nuts - arrows -.
- Remove left front muffler with decoupling elements.
- Remove nuts - arrows -.
- Remove right front muffler with decoupling elements.
- Remove driveshaft heat shield - A - - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.
- Tie up driveshaft to body.
- Remove bolts - arrows - on tunnel cross member.
- Have a second technician press the brake pedal.
CAUTION!
To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove collar bolt - 2 - at left and right drive axles - 1 -.
- Remove bolts - arrows - uniformly at left and right.
- Remove stabilizer.
- Disconnect electrical harness connector - 2 - at Level Control System Sensor.
- Disconnect connecting link - 1 - at control arm.
- Remove spring shock absorbers from control arm - arrow -.
- Remove guide control arm - 1 - and control arm - 2 - on subframe.
- Swing guide control arm - 1 - and control arm - 2 - outward.
CAUTION!
Guide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
- Repeat work procedure on opposite side of the vehicle.
- Remove heat shield above drive axle from transmission - arrows -.
- Remove drive axle from transmission flange.
CAUTION!
Do not damage brake hose!
- Swing wheel bearing housing outward and remove drive axle.
- Repeat work procedure on opposite side of the vehicle.
Prepare scissor lift platform:
- Equip scissor lift platform (VAS 6131) with support set (VAS 6131/10) and (VAS 6131/11) as follows:
* A washer must also be placed on the support element.
- 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 table (VAS 6131) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) or (VAS 6131/11) on front of engine as shown in illustration.
• Place a washer - arrows - between the support elements (VAS 6131/11-1) and the oil pan.
- Position support elements from (VAS 6131/10) at left and right on engine carrier and subframe 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).
- Mark installation position of subframe and engine carrier to longitudinal members using a felt-tip marker.
- Remove bolts - 1 - and - 4 -.
- Remove bolts - 2 - and - 3 - 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 engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- First lower engine/transmission assembly using scissor lift platform (VAS 6131) only approximately by dimension - a -.
• Dimension - a - = 80 mm.
- Remove heat shield for selector lever cable on left of transmission - arrows -.
- Press ball socket - 1 - of selector lever cable from selector shaft lever using Pry Lever - RMV Outside Mirror (80-200).
- Unclip locking plate - 2 - from selector lever cable bracket.
- Move selector lever cable clear.
• While lowering, carefully guide engine/transmission assembly with subframe out of engine compartment in order to prevent damage.
- Slowly lower engine/transmission subassembly downward.
- Remove scissor lift table (VAS 6131) under vehicle.