Engine Removing and Installing
Engine removing and installing
Special tools and equipment
^ 10-222 A Support bracket with legs 10-222 A/1
^ 10-222A/2 Additional hooks
^ 10-222A/12 Shackle
^ 10-222A/17 Spacer tube
^ 3033 Lifting tackle
^ 3213 Assembly device
^ T101 16 Engine stand
^ T40016 Transport bracket
^ VAG 1306 Drip tray
^ VAG 1331 Torque wrench (5...50 Nm)
^ VAG 1332 Torque wrench (40...200 Nm)
^ VAG 1383 A Engine/transmission jack
^ VAS 5024 Installation tool for spring-type clips
^ VAS 5051 Vehicle Diagnostic, Testing and Information System
^ VAS 5085 Step ladder
^ VAS 6100 Workshop crane
Not illustrated:
^ G 000 100 Grease (vehicles with manual transmission)
^ Cable tie
Engine, removing
The engine with transmission is removed in a forward direction.
WARNING: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
- Before removing engine check Diagnostic Trouble Code (DTC) memories of all control modules:
Refer to Diagnostic tester VAS 5051; Guided fault finding; Vehicle system tester
Note: When the engine is installed in the engine compartment some components cannot be removed or removed only with great difficulty Therefore determine which components are faulty before removing engine.
Work sequence
^ Switch off ignition and all electrical consumers and remove ignition key.
^ With ignition switched off disconnect battery Ground strap.
^ Release line -2- and bracket -5-. Remove cable -3-, pull it through bulkhead and disconnect it from right-hand longitudinal member.
Note: All cable ties which are opened or cut open when removing the engine, must be replaced in the same position when installing the engine.
^ Remove air cleaner with intake pipe up to throttle valve control module.
^ Remove noise insulation.
^ Removing front bumper:
^ Move lock carrier into service position: Lock Carrier And Front Bumper Reinforcement, Moving to Service Position
^ Extract refrigerant from air conditioning system:
^ Separate air conditioning system lines -2- and -3- at condenser and line -1- at reservoir:
Note: To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
^ Drain engine oil.
Note: Observe disposal regulations!
^ Remove oil filter housing complete with hoses, Refer to Oil Filter Housing, Service and Repair.
^ Drain coolant.
^ Separate hose connections (arrows) between transmission oil cooler and lines to manual/automatic transmission and collect oil which may leak out in a suitable container.
Note: Observe disposal regulations!
^ Separate lines to cooling coil at connections (arrows) and collect hydraulic oil which may leak out in a suitable container.
Note: Observe disposal regulations!
^ Remove hose (arrow) on suction side of power steering pump and collect hydraulic oil which may leak out in a suitable container.
^ Separate line -1- on pressure side of power steering pump and remove line -2-. Collect hydraulic oil which may leak out in a suitable container.
^ Remove lock carrier with attachments: Removal and Replacement
^ Remove pressure hose between combi-valve and secondary air injection pump.
^ Remove exhaust system (not exhaust manifold/catalyst), Refer to Powertrain management, Air Injection, Service and Repair
^ Disconnect coolant pipe -1- to Coolant Pump -V36- at longmember, left side.
^ Disconnect Ground strap (arrow) on engine and place to side.
^ Disconnect fuel supply and fuel return lines (arrow) at fuel rail.
WARNING: Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
^ Separate line to EVAP canister on bulkhead.
^ Disconnect all necessary lines at intake manifold upper part.
^ Seal lines so that fuel system is not contaminated by dirt etc.
^ Disconnect coolant hose and electrical connector from heater regulator (arrows).
^ Disconnect connectors on left of engine compartment.
^ Remove coolant system expansion tank.
^ Remove wiper arms and cowl panel:
^ Remove cover of protective housing for control modules.
^ Carefully pry off retainer bar with a screwdriver (arrow).
^ Release connector from control module and pull off.
^ Remove engine control module.
^ Remove relay carrier -1- from protective housing and pull out connector (arrow).
^ Disconnect engine wiring harness from central unit and place to one side.
^ Disconnect all connectors on bulkhead and release fastenings.
^ Disconnect all electrical connections as necessary from engine and place to one side.
^ Secure T40016 transport bracket to rear left of cylinder head with securing screw -1-.
Tightening torque: 25 Nm
^ Fit engine support bracket 10-222A with additional hooks 10-222A/2 and shackle 10-222A/12 as illustrated.
^ Remove propshaft heat shield from vehicle underbody.
^ Secure propshaft with assembly device 3213.
Vehicles with manual transmission
^ Unbolt propshaft from transmission:
Vehicles with automatic transmission
^ Unbolt propshaft from transmission:
Continuation for all vehicles
^ Unbolt drive shafts from transmission.
^ Remove drive shaft heat shields from transmission.
^ Remove drive shaft heat shields from transmission mount.
^ Secure transmission with engine/transmission jack VAG 1383 A.
^ Remove both transmission modules. No need to loosen transmission mounting -1-.
^ Remove front wheels.
^ Loosen bolted union -1- and pull upper links -2- off wheel bearing housing -3-.
^ Mark installation position of threaded connection -1- and lower locating sleeve -2- on left and right engine mountings.
^ Disconnect vacuum lines -3- at Left Electro-Hydraulic Engine Mount Solenoid Valve -N144-/Right Electro-Hydraulic Engine Mount Solenoid Valve -N 145-.
^ Disconnect both lower engine mountings.
^ Lower engine with transmission via support bracket 10-222A until following work sequences can be performed:
Vehicles with manual transmission
^ Disconnect selector mechanism from transmission.
Vehicles with automatic transmission
^ Disengage selector lever cable at transmission:
Continuation for all vehicles
^ Hook lifting tackle 3033 (item 2 and 11) into supplementary hooks 10222A/2 and lift slightly using workshop crane VAS 6100.
^ Lift engine with transmission until support bracket 10-222A/2 can be unhooked. To do this, turn stud out of shackle 10-222A/12.
^ Pull engine with transmission forward slightly and remove coolant hose to heat exchanger.
^ Check that all connections between bulkhead and engine have been separated.
Vehicles with manual transmission
^ Pull engine with transmission forward until clutch slave cylinder can be removed:
^ To do this unclip line (arrow) and remove bolt -1-.
Continuation for all vehicles
^ Lift out engine with transmission forward.
Note:
^ Guide the engine carefully when lifting out, to prevent damage to the bodywork.
^ Do not set the engine down on the sump or the liquid gasket between the upper end lower sump will be damaged. Use engine stand T10116 to hold engine.
^ Secure engine in engine and transmission stand VAS 6095 when working on engine.
Notes on installing
Work sequence
Install in reverse order but note following:
^ Check whether dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
^ Reconnect all lines, hoses and connections that were disconnected for removal sequence.
^ Replace bonded rubber mounting for oil filter housing, Refer to Oil Filter Housing, Service and Repair
^ Check electrical connections and routing:
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations
Vehicles with manual transmission
^ Top up transmission oil
Vehicles with automatic transmission
^ Top up ATF
Continuation for all vehicles
^ Connect A/C system lines:
^ Top up oil for power steering
^ Top up engine oil
^ Fill with coolant.
^ Check headlight adjustment and adjust if necessary
^ Perform a test drive and check all DTC memories:
^ Diagnostic tester VAS 5051; Guided fault finding; Vehicle system test
Observe the valid safety precautions when performing a road test.