Engine, Removing
Engine, removing
Note: During the following procedure the battery Ground strap must be disconnected Check first whether a coded radio is installed Obtain the radio code first, if necessary.
The engine is removed in a downward direction 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 the engine, must be replaced in the same position when installing the engine.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Remove left and right sound insulation
- Drain coolant.
- Remove battery and battery retainer.
WARNING:
^ Fire Hazard! Do NOT have anything in the area that can ignite fuel!
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
Engines: APK, AQY, BEJ, BER, BHP
- Pull off hose -1- (with white marking) and return hose -2- (with blue marking) and collect fuel that leaks out with a cloth.
- Pull hose off solenoid valve -3
Engines: AEG, AVH, AZG
- Disconnect the following hose connections and collect fuel that leaks 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)
Engines: BBW, BEV
- Disconnect fuel supply line -1- off union by pressing locking ring -2- into union -3-.
Continue for all vehicles
- Seal lines to avoid contamination of fuel system.
Note: Seal the intake ports in the intake manifold lower section with clean cloths.
- In preparation for further disassembly work disconnect connectors from following components (= Component Locations):
* Camshaft Position (CMP) sensor-G40
* Fuel Injectors -N30- to -N33-, unclip cable guide
* Engine Coolant Temperature (ECT) sensor -G62
* Engine speed (RPM) sensor-G28
* Knock sensor (KS) 1 -G61
* Knock sensor (KS) 2 -G66
* Oil pressure switch -F1
* Mass Air Flow (MAP) sensor -G70
* Throttle valve control module -J338
* A/C cut-out thermal switch -F163
Engine: BBW
- Valve -1- for camshaft adjustment -N205
- Ignition coils with power output stages -N70-1 -N 127-1 -N29 1-1 -N292
- Secondary Air Injection (AIR) pump motor -V1 01 -
Engine: BEJ, BER
- Ignition coils with power output stages -N70-1 -N 127-1 -N29 1-1 -N292
Engine: BHP
- Ignition coils (-N- and -N128-) with power output stage -N122
Engine: APK, AQY
- Ignition coil -N152
- Oil Level Thermal Sensor -G266
- Secondary Air Injection (AIR) pump motor -V1 01 -
Engine: AEG, AVH, AZG
- Ignition coils (-N- and -N128-) with power output stage -N122
- Secondary Air Injection (AIR) pump motor -V1 01 -
Engine: BEV
- Ignition coils with power output stages -N70-1 -N 127-1 -N29 1-1 -N292
- Secondary Air Injection (AIR) pump motor -V1 01 -
Continue for all models
- Remove air cleaner.
- Remove inter-connecting] coolant vacuum and intake hoses on engine.
- Remove intake manifold upper part (not BEJ engine).
Note: Seal the intake ports in the intake manifold lower part with a clean cloth.
Models with manual transmission
- Disconnect shift mechanism from transmission.
- Remove hydraulic clutch slave cylinder:
Note: The clutch pedal must not be operated.
Vehicles with automatic transmission
- Disconnect selector lever cable from transmission:
Continuation for all models
- Remove poly V-belt.
- Remove securing clamps for power steering pressure line.
- Remove power steering pump from bracket and lay to side; hoses remain connected:
Vehicles with air conditioning
- Remove air conditioner compressor.
- Note additional information and removal work.
Continue for all models
- Disconnect hoses from engine.
- Models with secondary air pump remove secondary air pump motor and bracket.
- Disconnect all electrical wiring from transmission] generator and starter and move clear.
- Disconnect all other electrical connections from engine and lay to one side as necessary.
- Unbolt pendulum support (arrows).
- Remove protective cover for right side inner constant velocity joint from engine.
- Remove right axle shaft and disconnect left axle shaft at transmission:
- Remove front exhaust pipe.
- Disconnect connector for oxygen sensor before catalytic converter and free wiring.
- Depending on version remove oil pan protection.
- Insert engine bracket T1001 2 in engine/transmission jack V.A.G. 1383 A.
- Secure engine bracket T1001 2 to front of cylinder block with securing bolt M10 x 25(8.8) to 40 Nm.
- Tighten securing nut on exhaust side hand tight.
- Lift engine and transmission lightly using engine/transmission jack V.A.G. 1383A.
- Unbolt engine side of assembly mounting from top of engine carrier (arrows).
Note: Use step ladder VAS 5085 or equivalent to remove securing bolts.
- Unbolt transmission side of assembly mounting from top of transmission carrier (arrows).
- Carefully lower engine with transmission.
Note: Engine and transmission must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines/wiring.