Notes on Removing
Notes on removing
The engine is removed downward together with the transmission.
CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing the engine.
Work sequence
- Remove engine cover.
- First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Disconnect connectors from ignition coils 1...6.
Note: Mark connector and component before pulling connector off.
- Remove ignition coils with final out stage for cylinders 1...6 using puller T10095.
- Remove battery and battery retainer.
- Remove air cleaner with intake hose
- Disconnect following hose connections and collect fluids that may leak out with a cloth:
1. vacuum hose to throttle valve control module -J338-,
2. fuel return hose (with blue markings),
3. fuel supply hose (with white markings).
Note: Press buttons on hose couplings to do so.
WARNING: Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
- Seal lines to avoid contamination of fuel system.
- Observe rules for cleanliness, Refer to Powertrain Management, Fuel Delivery and Air Induction, Service and Repair
- Remove center, left and right insulation trays:
- Pull connectors off thermal switch and radiator fan.
- Removing front bumper:
- Bring lock carrier into service position:
- Remove intake manifold, Refer to Timing Cover, Service and Repair
Note: Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth.
- Remove ribbed belt.
- Remove power steering pump on compact bracket and place to side; hoses remain connected
- Remove securing clamps for power steering pressure line.
Vehicles with air conditioning
- Observe additional information and removal work, Refer to Additional Information and Assembly Work on Models With Air Conditioning
Models with a manual transmission
- Disconnect selector mechanism from transmission:
- Separate hydraulic line to slave cylinder for hydraulic clutch:
Models with an automatic transmission
- Remove gate selector lever cable from transmission
Continuation for all vehicles
- Pull vacuum and breather hoses off engine.
- Separate connectors on following components:
Note: Mark connector and component before pulling connector off.
^ Engine Coolant Temperature (ECT) sensor -G62- with Engine Coolant Temperature (ECT) sensor -G2-,
^ After-run coolant pump -V51-,
^ Valve -1- for camshaft adjustment -N205-,
^ Camshaft adjustment valve (exhaust) -N318-1
^ Camshaft Position (CMP) sensor -G40-,
^ Camshaft Position (CMP) sensor 2 -G163
^ Injectors (-N30- to -N33-, -N83- and -N84
^ Engine speed (RPM) sensor -G28-,
^ Knock sensor (KS) 1 -G61-,
^ Knock sensor (KS) 2 -G66-,
Installation locations
- Disconnect all electric wires from transmission, alternator and starter and them move clear.
- Pull off/disconnect all other electrical connections from engine as necessary and place to one side.
- Drain coolant.
- Pull coolant hoses quick release couplings off radiator.
- Pull all coolant hoses off to engine using assembly tool for spring-type clamps VAS 5024.
- Removing drive shafts:
Refer to Transmission and Drivetrain
- Remove pendulum support:
- Remove front exhaust pipe with catalytic converter
- Remove alternator and compact bracket:
- Unscrew bracket for secondary air injection pump motor -V101- from oil pan and cylinder block.
- Install engine bracket 3395 onto engine/transmission jack VAG 1383 A
- Install engine bracket 3395 to cylinder block and tighten securing nuts -1-to 40 Nm.
- Lift engine and transmission slightly using engine/transmission jack VAG 1383 A
- Unbolt engine side of assembly mounting from engine bracket at top -arrows-.
Note: Use ladder VAS 5085 to remove securing bolts.
- Unbolt transmission side of assembly mounting from top of transmission carrier-arrows-.
Note: Use ladder VAS 5085 to remove securing bolts.
- Carefully lower engine with transmission.
Note: Engine with transmission must be guided carefully, when lowering, to prevent damage to bodywork.