Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Shackle (10 - 222 A /12)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Sling (2024 A)
• Hose Clip Pliers (V.A.G 1921)
• Shop Crane (VAS 6100)
• Lift Arm Ext./Workshop Hoist (VAS 6101)
• Engine Bung Set (VAS 6122)
• Drip Tray (VAS 6208)
• Transmission Lift Hook (T40013)
• Locking Tool (T40098)
• Spanner Wrench (3212)
Procedure
• Remove the engine upward without the transmission.
• Collect escaping coolant in a clean container for disposal or reuse.
• During installation, cable ties must be installed at the same location.
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- Switch off ignition and remove ignition key.
- Remove the luggage compartment cargo floor - 3 -.
- Remove the bass box - 2 -.
- Fold back the carpet - 1 - over the flap.
- Press the release tabs - arrows - and open the flap - 1 -.
- Open the cover - 1 - over the battery (GND) ground terminal post.
- Disconnect the ground (GND) cable - arrow - from the battery terminal.
- Remove the engine cover - arrows -.
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.
- Remove the left and right front wheels.
- Remove left and right front wheel housing liners..
- Remove the noise insulation - 1 - and - 2 -.
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 ribbed belt.
- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory assembly bracket.
- Place the (VAS 6208) under the engine.
- Lift the clamps and open the drain - 1 - and let the coolant drain out and then remove the connection - 2 - from the radiator.
- Loosen the hose clamp - arrow -, pull of the air guide hose and move it to the side.
- Remove the nut - arrow - on the right longitudinal member and free up the ground (GND) wire.
The decoupling elements in the front muffler could be damaged.
• Do not bend decoupling elements in front muffler more than 10°.
- Loosen the threaded connections - arrows - and slide the clamping sleeves to the rear.
- Slightly lower the front muffler and tie it to the crossbrace - arrow -.
- Disconnect electrical connector - arrow - on steering gear.
- Remove the bottom cover - 1 - from the transmission - arrow -.
- Remove the three drive plate bolts - arrow - by turning the crankshaft 120° in direction of engine rotation.
- Disconnect solenoid clutch electrical connector - 1 - on A/C compressor.
Risk of injury from refrigerant.
• The air conditioning refrigerant circuit must not be opened.
- Remove A/C compressor bolts - arrows -.
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Tie up the compressor with the refrigerant lines attached to the longitudinal member.
- Remove the coolant fan electrical connector - 1 - form the bracket and disconnect it by sliding the retainer back - arrow - and pressing the release down.
- Free up the electrical wiring harness to the coolant fan control module.
- Open the clamps - 1 - and - 3 - and remove the coolant hoses.
• Ignore - 2 - and - arrows -.
- Loosen the hose clamps - arrows - and remove the air guide pipe.
- Disconnect the connector from the charge air pressure sensor (G31) - 1 - and free it up.
- Using a (3212) as a counterholder, remove the bolts - arrows - and remove the power steering pump ribbed belt pulley.
- Remove bolts - 1 - and - 3 -.
• Ignore - 2 -.
- Remove the power steering pump with the hydraulic lines connected to the longitudinal.
- Open the clamp - 2 - and remove the coolant hose.
• Ignore - 1 -.
- Remove the bolts - 1 - and - 2 - and then move the coolant pipe, with the coolant hoses still connected - arrows -, upward.
- Disconnect the connectors - 1 and 4 - from the oil pressure switch (F22) and remove the reduced oil pressure switch (F378).
- Remove the air duct - arrows -.
- Disconnect the connector - 2 - from the mass airflow (MAF) sensor (G70).
- Open the clamp - 3 - and remove the air guide hose from the mass airflow (MAF) sensor.
- Remove the air filter housing - 1 - upward.
Risk of contamination to the fuel system.
• Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect fuel supply hose - 1 - by pressing release ring.
- Remove the hose - 2 - from the EVAP canister.
- Remove the bolts - 1 - and nuts - 2 - and - arrow - and remove the strut tower brace.
- Remove the left and right foam block - 1 - and - 2 -.
- Remove gasket - 3 -.
- Open the clips - 1 - and remove the plenum chamber cover - 2 -.
- Release the retainer - arrow A - and open the cover - arrow B -.
- Remove the nuts - 1 - and - 2 - for the electrical wires.
- Remove the electrical connector - 3 - from the bracket and disconnect it.
- Remove the bolt - 4 - and the terminal 30 wire junction 2 (TV22) from the plenum chamber bulkhead - 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.
- Free up the wiring harness - 3 - to the generator and starter using the (80 - 200).
- Free up the wiring duct by releasing the retainer - arrow B - and pulling the duct forward - arrow A -.
- Disconnect the vacuum connection - 1 - from the plenum chamber bulkhead by remove the vacuum hose - 2 - on the back side - arrow -.
- Remove the bolt - 2 - and the nut - 3 -.
- Remove the filler neck - 1 - with the filler tube from the washer fluid reservoir and the opening in the body - arrow -.
- Remove the nut - 5 - and free up the ground (GND) wire.
- Remove the bolts - 1, 2 and 4 - and remove the E-box cover - 3 - in the engine compartment - arrow -.
- Release the retainers - arrows A - and remove the engine control module - arrow B -.
- Disconnect the electrical connector - 2 - if applicable.
- Disconnect the connectors - 4 - and the wire - 3 -.
- Open the tabs - arrow - and fuse panel B (SB) - 1 -.
- Disengage the engine wiring harness on the E-box and free it up.
- Release the retainers - arrows A - and remove the wiring bushing - 2 - upward - arrow B -.
- Lay the wiring harness on the engine and secure the engine control module against falling down.
• Ignore - 1 -.
- Mark the coolant hoses - 1 - and - 2 -, open the clamps and then remove the them.
- Press the coolant hoses with hose guide in the plenum chamber.
• Disregard - arrow -.
- Disconnect the connectors and free up the wires.
1. For the heated oxygen sensor (G39)
2. For the oxygen sensor after three way catalytic converter (G130)
- Remove the nuts - arrows - and push the catalytic converter to the rear.
- Remove the starter from the transmission and leave it in the installation position
• The bolt - 2 - attaches the starter to the transmission and has an additional spacer sleeve - arrow -.
- Install (T40013) on the transmission and close locking device.
- Position the (10 - 222 A) on the left and right suspension strut tower as shown in the illustration.
- Attach the transmission and the spindle to the (10 - 222 A /12) and to the (T40013).
• The installation location is shown with the engine removed.
- Attach the (2024 A) to the engine and to the (VAS 6100) with the (VAS 6101) as illustrated.
• To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
Loose engine support bridge components could cause an accident.
• Secure the mounting hooks and pins on the engine support bridge using securing pins - arrows -.
- Remove the left and right bolts - 1 - from the engine mount.
- Remove the nut - 2 - and free up the electrical wiring bracket.
• Disregard - arrow -.
- Lift the engine until the engine mount is free.
- Turn the spindle on the (10 - 222 A).
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.
• A second technician is needed while removing the engine to make sure the hood is opened all the way.
- Lift the left and right locking springs - arrow - with a small screwdriver and remove the top of the gas-filled strut - 1 - from the ball pin - 2 -.
- Remove the engine from the transmission and lift it out of the engine compartment.
- Press the gas-filled struts back onto the ball studs.