Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Remove Outside Mirror (80-200)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor Lift Table (VAS 6131 A) with Support Set (VAS 6131/10), (VAS 6131/11) and (VAS 6131/12)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamps Up to 25 mm Diameter (3094)
• Hose Clamp Pliers (VAS 6362)
• Tension Strap (T10038)
Procedure
• With lock carrier installed, engine is removed downward with transmission and subframe.
• During installation, all cable ties must be re-installed at the same location.
• Collect escaping coolant in a clean container for disposal or reuse.
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.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- Switch off ignition and remove ignition key.
- Disconnect the Ground (GND) cable - arrow - from the battery terminal.
- Remove the engine covers - arrows -.
CAUTION!
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.
- Open coolant reservoir cap.
CAUTION!
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.
- Pivot the tensioner clockwise - arrow - to release the tension on the ribbed belt.
- Remove ribbed belt and release tensioning device.
- Remove the left and right front wheels.
- Remove noise insulation.
- Place (VAS 6208) under engine.
- Open the drain plug - 1 - and drain the coolant.
- Disconnect the right, lower coolant hose from the radiator, to do this, lift the retaining clip - 2 -.
- Remove the coolant hose from the engine oil cooler by loosening the hose clamp - arrow - and letting the coolant drain out.
- Disconnect the connector - 1 - on the A/C Compressor Regulator Valve (N280).
CAUTION!
Risk of injury from refrigerant.
• The air conditioning refrigerant circuit must not be opened.
- Remove A/C compressor bolts - arrows -.
CAUTION!
Danger of damaging the refrigerant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Attach the A/C compressor with the lines still attached to the left side of the vehicle.
• To collect escaping power steering fluid, lay a cloth under the separating point.
- Clamp off the power steering pump hydraulic hose - 1 - with a (3094).
- Remove the hydraulic oil hose from the power steering pump.
- Disconnect the hydraulic pipe - 2 - from the power steering pump and lay it on top of the longitudinal member.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Disconnect electrical connector - 3 - at Secondary Air Injection (AIR) Pump Motor (V101) and free up electrical wiring.
• Ignore - 1 and 2 -.
- Remove the bolts - arrows - and remove the torque support from the engine.
• Follow the rules for clean working conditions when working on the multitronic transmission.
- Place the (V.A.G 1782) under the separating point.
- Loosen the union nuts and remove the ATF pipes - 2 - and - 3 -.
• Ignore - 1 -.
- Remove the nut - arrow - for the Ground (GND) cable on the right longitudinal member.
- Remove the coolant hose leading to the back of the heater core; do to so, lift the retaining clamps - arrow -.
- Remove bolt - arrow -.
- Disconnect the electrical connector to the Engine Coolant Level Warning Switch (F66) on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses - 1 - and - 2 - attached.
- Free up the electrical wire.
- Loosen the clamp - arrow - and remove the coolant hose from the coolant pipe.
- Open the clips - arrows - and remove the left front coolant hose.
- Remove the coolant hose - arrow - from the front coolant pipe by lifting the retaining clamp.
- Press the release button - 1 - and free up the vacuum hose - arrow - on the Leak Detection Pump (V144).
- Remove the bolts - arrows -, remove the air guides - 1 - and - 2 -.
CAUTION!
There is a risk of contamination.
• Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
CAUTION!
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
- Remove the fuel supply hose from the high pressure pump - arrow - and free it up.
- Free up the fuel line - 4 - and the line - 1 - to the EVAP canister on the air filter housing and on the air guide pipe.
- Remove the vacuum hose - 2 - from the air guide hose connection.
- Remove the air guide pipe by loosening the hose clamp - 3 - and opening the clips - arrows -.
- Disconnect the connector - 1 - on Evaporative Emission Canister Purge Regulator Valve (N80) and then disconnect the vacuum hose - 2 -.
- Remove the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from the bracket and lay it aside with the hose connected.
- Remove the brake booster check valve - arrow - from the plenum chamber bulkhead.
- Open the clips - arrows - and remove the air filter housing upper section.
- Remove the pin from spreader clips - 2 -.
- Remove the air filter housing lower section. Then press the release button and disconnect the hose - 1 - from the secondary air injection pump.
Vehicles with Intake Air Switch-Over Valve (N335):
- Disconnect the vacuum line - 1 -.
- Disconnect the - 2 - Intake Air Switch-Over Valve (N335) connector on the back of the air filter housing lower section.
• Ignore - 3 -.
All Vehicles
- Remove the front secondary air hose - arrow - from its bracket and disconnect it; to do so, press the release buttons.
- Remove the nuts - 3 - and then remove the right bracket from the plenum chamber bulkhead.
- Remove the nut - 1 - on the positive terminal pick-off.
- Remove the Ground (GND) bolt - 2 -.
- Remove the nuts - 1 - and then remove the left bracket from the plenum chamber bulkhead.
- Remove the nut - arrow - on the left suspension strut tower and free up the Ground (GND) wire.
- Remove the windshield wiper arms - arrows -.
- Remove the seal - 1 - and remove the plenum chamber cover - 2 -.
CAUTION!
Danger of causing damage to the wind cowl.
• To prevent the cowl grille - 1 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.
- Remove the screws - arrows - and remove the cowl panel trim from the windshield.
- Remove the bolts - 1 - and - 3 - and then remove the tower brace - 2 -, if equipped.
- Remove the brake booster vacuum line - arrow - on the plenum chamber bulkhead.
- Remove the bolts - arrows - and the left engine compartment E-box cover.
- Release the retainers, pull the fuse holder - 1 - and then the 3-socket relay carrier - 4 - upward.
- Disconnect the electrical connectors - 3 -.
- Disconnect the three front connectors - 2 - at the rear on the connector strip.
- Disengage the engine wiring harness on the E-box and free it up.
- Remove the bolts - arrows - and the right engine compartment E-box cover.
- Open the cover - 1 - with a screwdriver - arrow - and remove it.
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.
- Using a screwdriver, carefully pry off the mounting clamp - 3 - - arrows 1 and 2 - and remove the engine control module from the E-box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Unclip the suppression capacitor - 5 - from the bracket in the E-box.
- Disconnect the electrical connector - 4 - at the back on the connector strip.
- Disconnect the electrical wire connections - 1 - and - 2 -.
- Free up the electrical line up to the generator using the (80 - 200).
- Lay both wiring harnesses on the engine and secure the engine control module against falling down.
CAUTION!
Danger of personal injury and of damage to the brake discs and wheel bearing.
• To loosen drive axle collar bolt, vehicle must not be resting on wheels.
• The brake discs must be secured from turning by 2 wheel bolts.
- Have a 2nd technician apply to the brake pedal.
- Remove the left and right collar bolt - 2 - on the drive axles - 1 -.
- Remove the left and right nuts - 1 -.
- Remove the left and right bolt - 2 - and remove the stabilizer bar.
- Disconnect the connector - 2 - on the Left Front Level Control System Sensor (G78).
- Remove the nut - 1 - and remove the coupling rod from the control arm.
CAUTION!
Risk of damaging axle joints on upper control arms.
• Support wheel bearing housing.
- Tie up wheel bearing housing using (T10038) as shown in illustration.
- Remove the bolt - arrow - and remove the suspension strut from the control arm.
- Remove the guide control arm nut - 1 - and the control arm nut - 2 - on the subframe; then remove the bolts.
- Swivel the guide control arm - 1 - and the control arm - 2 - toward the outside.
CAUTION!
The control arm and the guide control arm could be damaged if they are allowed to hang free.
• Tie the guide control arm and the control arm to the wheel bearing housing - arrows - as illustrated.
- Remove the bolts - arrows - and remove the left drive axle heat shield.
- Remove the drive axle from the transmission flange shaft.
CAUTION!
Risk of damaging brake line.
• Carefully remove the drive axle.
- Swivel the wheel bearing housing toward the outside and remove the drive axle.
- Repeat the procedure on the other side of the vehicle.
- Remove the bolts - arrows - and remove the crossbrace from the subframe.
- Separate the exhaust system at the clamping sleeves - 1 - and - 2 -.
- Remove the bolts - arrows - and remove the front transverse beam.
Prepare scissor lift platform:
- Set up the (VAS 6131 A) and (VAS 6131/10) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position the (VAS 6131 A) horizontally.
• Note bubble level (sight glass) on support platform.
- Move the (VAS 6131 A) under the engine/transmission subassembly.
- Attach mounting elements from the (VAS 6131/10) at the front of the engine as shown in the illustration.
- Ensure threaded spindles are completely installed.
- Attach mounting elements from (VAS 6131/10) at left and right on subframe as illustrated.
- Attach support elements from the (VAS 6131/10) to the back of the tunnel crossmember as illustrated.
- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.
- Attach mounting element base plates to (VAS 6131 A) and tighten to 20 Nm.
- Remove the bolts - arrows - on the tunnel crossmember.
• The installation location is shown with the front exhaust pipes removed.
- Remove bolts - 1 -.
- Mark location of subframe and both engine mount brackets to the longitudinal members with a felt-tip pen.
- Remove the bolts - 2, 3 and 4 - in diagonal sequence in steps.
CAUTION!
Risk of damaging hose and wiring connections as well as engine compartment.
• Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
• Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.
- Lower the engine/transmission subassembly on the (VAS 6131 A) 100 mm at first.
• Mark selector lever cable bracket installation location.
- Remove the bolt - 1 - on the cable mounting bracket.
- Remove the selector lever cable ball socket - 2 - from the transmission shift lever using the (80 - 200).
CAUTION!
Danger of causing damage to the selector lever cable.
• Do not bend or kink selector lever cable.
- Lower the engine/transmission subassembly using the (VAS 6131 A).
- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.