Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Hose Clip Pliers (V.A.G 1921)
• Drip Tray (VAS 6208)
• Locking Tool (T40098)
• Engine Support Bridge (10 - 222 A)
• Engine Support Feet (10 - 222 A /8)
• Shackle (1 Set=2 Pieces) (10-222 A/12)
• Shop Crane -Load Cap=700-1200 kg (VAS 6100)
• Engine Sling (2024 A)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Gearbox Support (T10337)
• Release Tool f/ Rev. Light Switch Conn. (T40138)
Procedure
Risk of vehicle tipping over with engine removed.
• Secure vehicle. Luggage compartment must be empty for this.
• Remove the engine without the transmission upward.
• Collect escaping coolant in a clean container for disposal or reuse.
• When installing, bring all cable ties back to same positions.
• In order to be able to turn the driveshaft on an AWD vehicle to remove it, release the electro-mechanical parking brake before disconnecting the battery.
Danger of causing damage to other electronic components when disconnecting the battery.
• Follow the instructions when disconnecting the battery.
- Disconnect the battery.
- Remove the left and right front wheels.
- Remove left and right front wheel housing liners.
- Remove the noise insulation.
- Install the lock carrier in service position. Radiator Support
- Remove the front exhaust pipe/front muffler. Refer to Front Exhaust Pipe and Front Muffler
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Loosen the air intake hose - 2 -.
- Remove the air filter housing upward - arrows -.
- Remove the engine cover - arrows -.
- Remove the seal - arrow -.
- Unclip the plenum chamber covers - 1, 2 and 3 - and remove it.
- Remove the left and right foam block - 1 - upward - arrows -.
- Release the retainer - arrow A - and open the cover - arrow B -.
- Remove the nuts - 1 through 3 - for the electrical wires.
- Remove the electrical connector - 4 - from the bracket and disconnect it.
- Remove the bolt - 5 - and remove the wire junction from the tower brace - arrow -.
- Release the retainers from the wheel housing side using a 5.5 mm open end wrench - 1 - and remove the wiring bushing - 2 - upward.
- Open the wiring duct by opening the release - arrow B -, pull the wiring duct forward - arrow A - and free up the wires.
- Remove the nut - 1 - and tilt the washer fluid filler neck upward - arrow A -.
- Remove the filler neck - 2 - with the filler tube from the washer fluid reservoir and the opening in the body - arrow B -.
- Remove the bolts - 1 - and nuts - 2 - and the tower brace - 3 -.
- Remove the bolts - arrows - and the engine compartment E-box cover.
- Remove the nut - 1 - and free up the wire.
- Release the retainers - A arrows - and remove the engine control module - arrow B -.
- Disconnect the connectors - 4 - and remove the nut - 3 - for the electrical wire.
- Disconnect the connector - 2 - if applicable.
- Release the retainers - arrow - and remove the relay carrier with the fuse holder - 1 -.
- Release the retainers - A arrows - and remove the wiring bushing - 1 - upward - arrow B -.
- Disengage the engine wiring harness at the engine compartment E-box and free it up.
- Lay the wiring harness on the engine and secure the Engine Control Module (ECM) so that it cannot fall.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.
- Open the coolant reservoir cap.
- Place the (VAS 6208) under the engine.
- Open the drain - 1 - and let the coolant drain out and then remove the connection - 2 - from the radiator.
- Remove the left and right nuts - 3 - and remove the longitudinal braces - 2 -.
- Loosen the hose clamp - arrow -, pull off the air guide hose and move it to the side.
- Remove the nut - 1 - on the right longitudinal member and free up the ground wires.
- Remove the nut - 2 - for the bracket with the electrical wires on the right side of the vehicle.
- Disconnect the coolant fan electrical connector - 1 - by sliding the retainer back - arrow - and pressing the release down.
- Lay the wiring harness on the engine and secure it from falling down.
- Disconnect the vacuum connection - 2 - from the plenum chamber bulkhead by remove the vacuum hose - 3 - on the back side - arrow -.
- Remove the nut - 5 -.
- Remove the coolant hoses - 1 through 4 - and remove the plenum chamber bulkhead.
- Remove the bolts - 2 to 6 -.
• The bolt - 2 - attaches the starter to the transmission and has an additional spacer sleeve - arrow -.
• Pay attention to the spacer sleeve with removing or installing the engine - arrow -. The spacer sleeve must be inserted between the starter and the transmission.
- Remove the coolant hose - 2 - and the permanent ventilation - 1 -.
- Remove the permanent ventilation - 1 - and coolant hose - 2 - from the coolant reservoir.
- Loosen the hose clamps - arrows - and remove the air guide hose.
- Disconnect the charge air pressure sensor (G31) - 1 - connector and free it up.
- Remove the catalytic converter.
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.
- To release ribbed belt tension, rotate tensioner in direction of - arrow -.
- Secure the tensioner with the (T40098).
- Remove the ribbed belt.
- Disconnect solenoid clutch electrical connector - 1 - on Air Conditioning (A/C) compressor.
Refrigerant can cause serious personal injury.
• Do not open the air conditioning refrigerant circuit.
- Remove A/C compressor bolts - arrows -.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Tie up the compressor with the refrigerant lines attached to the longitudinal member.
• The power steering pump hydraulic lines remain connected.
- Remove the bolts - 1 - from the front through the belt pulley and then remove the bolt - 2 - from the back.
• The power steering pump is shown in the illustration without the belt pulley and without the hydraulic lines.
- Remove the power steering pump with the hydraulic lines connected to the longitudinal.
Follow cleanliness precautions when working on the fuel supply system.
- Disconnect the fuel supply hose - 1 - and return hose - 2 -.
- Support the transmission with the (V.A.G 1383 A) and (T10337).
- Remove the bolts from the tunnel crossmember - arrows -.
- Lower the transmission with the (V.A.G 1383 A) to dimension - a -.
• Dimension - a - = 80 mm maximum.
- Disconnect the connector - 1 - on the back-up lamp switch (F4) using the (T40138) and free it up.
- Unclip the wire - A - from the transmission and disconnect the connector - C -.
- Lift the transmission with the (V.A.G 1383 A) and install the bolts - arrows - for the tunnel crossmember.
- Remove the lower cover - 1 - from the transmission - arrow -.
- Remove the 3 drive plate bolts - arrow -. Turn the crankshaft an additional 120° in the direction of engine rotation.
- Remove the bolt on the starter - 1 - from the engine side.
- Remove the starter from the transmission and leave it in the installation position.
- Remove the remaining bolts - 7 through 10 - that attach the engine to the transmission.
- Install the (10 - 222 A) with (10 - 222 A /8) on the left and right strut towers, as shown in the illustration.
- Attach the transmission and spindle with the (10-222 A/12).
• To improve clarity, the removed engine is shown.
- Gently tension the spindle by the (10-222 A).
- Engage (2024 A) on engine and on (VAS 6100) as shown in illustration.
Lifting hooks and alignment pins on the engine sling must be secured with securing pins.
- Remove the left and right engine mount bolts - 1 -.
• Ignore - arrow -.
- Lift the engine until the engine mount is free.
- Turn the (10-222 A) spindles.
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 lift and guide the engine out of the engine compartment.
- Remove the engine from the transmission and lift it out of the engine compartment.