Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Adapter (10 - 222 A /7)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Lifting tackle (2024 A)
• Lifting tackle (3033)
• Hose clamps up to 25 mm diameter (3094)
• Used oil collecting and extracting device (V.A.G 1782)
• Hose Clamp Pliers (VAS 6362) instead of Hose Clamp Pliers (V.A.G 1921)
• Shop Crane (VAS 6100)
• Lift Arm Extension for Workshop Crane (VAS 6101)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (VAS 6340)
• Engine Bung Set (VAS 6122)
• Support (T40137)
Procedure
• The engine with transmission is removed upward.
• During installation, all cable ties must be re-installed at the same location.
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.
- Remove the passenger seat.
- Install protective body covers. Refer to => [ Protective Body Covers, Installing ] Protective Body Covers, Installing.
- Remove the left - 1 - and right - 3 - engine compartment trim.
- Remove the engine cover - 2 -.
- Bring the rear lid into the service position.
- Remove the left and right side panel cover.
- Empty coolant circuit.
- Extract the power steering oil from the reservoir with the Used Oil Collection and Extraction Device (V.A.G 1782).
- Remove the air ducts - 1 - and - 2 -.
- Remove the rear - 1 - and front - 2 - noise insulation.
- Remove the left and right rear wheels.
- Remove the left and right rear wheel housing liners.
- Remove the rear impact absorber.
- Remove left and right tail lamp assemblies.
- Remove the rear lid rack.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- With the ignition switched off, disconnect the battery Ground (GND) cable - arrow -.
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 coolant reservoir cap.
• Collect escaping coolant in a clean container for disposal or reuse.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Remove the drain plug - 2 - on the coolant thermostat housing and drain the coolant.
- Remove the coolant hose - 1 - and let the coolant drain.
- Remove coolant hoses - 1 through 4 -.
• The installation location is shown with the engine removed.
- Drain engine oil.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Remove the bolts - arrows - and remove the oil line retaining plate - 1 -.
- Remove the oil lines from the upper section of the oil pan.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove the driveshaft.
CAUTION!
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Disconnect refrigerant line - arrow -.
- Remove the bolt - arrow - and remove the refrigerant line from the reservoir and place it in the engine compartment.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove engine bracket left and right bolts - arrows -.
- Remove the bolts - 2 - and the oil line from the oil tank.
- Remove the Ground (GND) wire bolt - 1 -.
CAUTION!
There is a risk of contamination.
• There is still oil in the oil line.
- If the engine and transmission should be separated after removing them, remove bolt - 9 - and nuts - 1, 7 and 8 - from the engine to transmission connection.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Disconnect the power steering hydraulic fluid line at the threaded connection - 1 -.
- Remove the clamp screw - 2 -.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Remove the bolt - arrow - and the transmission fluid lines from the transmission fluid thermostat.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove the left and right drive axle - 2 - from the transmission flange shafts.
- Loosen hose clamps - 2 - and - 4 - and remove the air filter housing.
- Remove the air filter housing bolts - arrows -.
- Remove the boots - 1 - and - 6 - from the air filter housing.
- Disconnect the electrical connectors:
3 on the Mass Air Flow (MAF) Sensor 2 (G246)
5 at Mass Air Flow (MAF) Sensor (G70)
- Remove the air filter housing and mass air flow sensors.
- Free up the brake booster vacuum hose - 5 -.
- Remove the vacuum hose - 2 - from the intake manifold.
- Loosen the hose clamp - 1 - and lay aside the air guide hose with connected brake booster vacuum hose - 5 -.
• Ignore - 3 and 4 -.
CAUTION!
Risk of injury from fuel.
• To reduce residual pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Remove the fuel supply line - arrow - and lay aside.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove the left and right nuts - 1 - and the bolt - 2 - and then remove the heat shield.
- Remove the left and right nut - 1 - and bolt - 3 -.
- Free up the vacuum line - 2 -.
- Free up electrical wiring harness - arrow -.
- Pull the heat shield off the threaded pin just a little.
- Loosen the clamp - 1 - on the left exhaust system tract, tilt it outward with the spring element - arrow - and remove the clamp.
- Repeat the procedure on the other side of the vehicle.
• Two people are needed to remove the muffler.
- Remove the nut - arrow - on the heat shield.
- Remove the vacuum hose - 1 - from the exhaust flap vacuum actuator and free it up.
- Remove the bolts - 2 - and - 4 - and remove the sleeve - 3 -.
- Repeat the procedure on the other side of the vehicle.
- Remove the muffler.
- Remove the left and right bolts - 1 - and - 2 - and remove the stabilizer bar.
- Remove the exhaust flap vacuum actuator vacuum hose - 1 - from the T-connector - 2 - and move to the left.
- Disconnect the electrical connector - arrow - on the Exhaust Flap Valve 1 (N321) and free up the electrical wire.
- Remove vacuum hoses - 1 - and - 2 - on the Y-connector and free them up.
- Remove the bolts - arrows - and the vacuum reservoir.
- Remove crankcase ventilation hoses - 1 - and - 4 - from the oil tank by pressing the release buttons.
- Free up the crankcase ventilation hose on the engine compartment crossmember - arrows -.
- Remove the bolt - 3 - on the retaining clamp.
- Move the crankcase ventilation hose forward.
• Ignore - 2 -.
• To collect escaping power steering fluid, lay a cloth under the separating point.
- Remove the power steering hydraulic fluid supply line - 1 -.
- Remove the bolts - 2 - and lay aside the power steering hydraulic fluid reservoir.
- Remove the left and right bolts - arrows -.
- Remove the bolt - 3 - on the wiring harness retaining clamp.
- Free up the wiring harness on the engine compartment crossmember.
- Remove bolts - 1 -.
- Remove the left and right bolts - arrows -.
- Mark the left and right spacer plates - 2 - with a felt tip pen so they can be reinstalled in the same location and remove them.
- Remove the crossmember from the engine compartment.
• To collect escaping motor oil, lay a cloth under the separating point.
- Remove the bolt - arrow - and the oil line - 1 - from the oil cooler carrier.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Disconnect electrical connector - 5 -.
- Remove bolts - 1 - and - 2 - and the oil tank with oil return line - 3 -.
• The bolt is reached - 2 - from the left wheel housing side.
• Ignore - 4 -.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
Vehicles with manual transmission:
- Press the sliding sleeve forward as far as the stop - arrow 1 -.
- Turn the sliding sleeve right as far as the stop - arrow 2 - until it engages.
- Remove the cable retainer - A - from the respective shift cable - B -.
- Remove lock washers - 1 - and - 2 -.
- Remove the shift cables from the bracket and free up on the engine.
- Remove the bolts - arrows - and the bracket.
• To collect escaping brake fluid, lay a cloth under the separating point.
- Clamp off the hose/line assembly with Hose Clamps Up to 25 mm Diameter (3094).
- Remove the banjo bolt - arrow - and lay the hose/line assembly aside.
CAUTION!
Risk of contamination from escaping brake fluid.
• Do not press the clutch pedal if the hose/line assembly is disconnected from the clutch slave cylinder.
Vehicles with R tronic:
- Remove the bolt - arrow - and lay aside the angle bracket with electrical connector.
All Vehicles
- Remove the secondary air hose - 1 - by pressing the release buttons.
- Disconnect the electrical connector - 2 - on the Secondary Air Injection (AIR) Pump Motor (V101).
• ignore.
- Remove the nut - arrow - and free up the electrical wiring harness.
- Remove the vacuum hose - 1 - on the EVAP canister by pressing the release button.
- Free up the hose.
• Ignore - 2 - and - arrows -.
- Free up the electrical wiring harness on the right longitudinal member.
- Disconnect the electrical connector - 2 - on the Engine Coolant Level (ECL) Warning Switch (F66).
- Remove the coolant hoses - 1 - and - 3 -.
- Remove bolts - 5 -.
- Slide the coolant reservoir forward slightly - arrow - and remove it from the bracket.
- Remove the coolant hose - 4 -.
- Remove the bolt - arrows - and the coolant reservoir bracket.
- Remove the right sill trim strip, lower right A-pillar trim, rear shelf and right side trim.
- Remove the Right Rear Mid/Low Range Speaker (R160).
Vehicles with R tronic:
- Disconnect electrical connectors - 1 - and - 2 - on the Transmission Control Module (J217).
All Vehicles
- Remove the bolts - arrows - on the relay carrier and fuse carrier.
- Remove the positive wire - 4 -.
- Disconnect the electrical connectors - 3 - on the connector strip.
- Remove the Ground (GND) wire bolt - 5 -.
- Free up the wiring harness.
• To unclip spiral clip, use Pry Lever - Rmv Outside Mirror (80 - 200).
- Mark the relay and the relay socket for later reinstallation.
- Remove the relay carrier and relay.
- Remove the relay socket from the relay carrier by releasing all the retainers - A arrows -.
- Remove the fuse socket from the relay carrier by pressing the retainer - B arrows -.
- Remove the right rear fuse holder base plate from the bracket.
- Release the retaining clamps - arrows - and press fuse holders - 1 - and - 2 - back out of the base plate.
- Free up the engine wiring harness and carefully guide it through the engine compartment.
- Fold the floor covering back in the right A-pillar area.
- Turn fasteners - 1 - and - 3 - 90° counterclockwise and open the cover - 2 - over the main fuse box.
- Remove the nut - 2 - for the battery positive wire - 1 -.
- Free up the battery positive wire up to the engine compartment, pull it back and out and lay it on the engine.
• To unclip spiral clip, use Pry Lever - Rmv Outside Mirror (80 - 200).
- Remove the Ground (GND) wire bolt - 1 -.
- Loosen the nuts - arrows -, press the retaining clips to the side and remove the Engine Control Module (ECM) 2 (J624).
- Free up the electrical wire and lay the Engine Control Module (ECM) 2 (J624) with wires connected on the engine.
- Repeat the procedure on the other side of the vehicle.
• Secure the engine control modules against falling off.
- Remove the left and right transmission mount bolts - 1 - while counterholding them with an open-end wrench - 2 -.
- Tighten the Lifting Eye for Removing Gearbox (T40137) on the transmission to 20 Nm.
- Remove the Engine Sling (2024 A) eye by removing the pins - 1 -.
- Install the Engine Sling (2024 A) eye as shown in the illustration and secure the pins - 1 - with a splint.
- Engage the Engine Sling (2024 A) in the lifting eyes on the front of the engine.
CAUTION!
There could be an accident if suspension components are not secured.
• Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.
- Engage the Lifting Tackle (3033) on the engine and on the shop crane with an Adapter (10 - 222 A /7) as shown in the illustration.
CAUTION!
Risk of damaging hose and wiring connections as well as engine compartment.
• Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.
• Carefully lift the engine/transmission subassembly out of the engine compartment.
- Raise the engine-transmission assembly with the Shop Crane (VAS 6100) and carefully guide it back and out.
CAUTION!
There is a risk of damaging the lower section of the oil pan.
• Do not place the engine-transmission assembly on the engine oil pan, on the workbench or on the floor.
- Place the engine-transmission assembly on the Scissor Lift Table (VAS 6131 A). Refer to => [ Engine-Transmission Assembly, Placing on the Scissor Lift Table ] Engine-Transmission Assembly, Placing on the Scissor Lift Table.