Engine Removing
.Engine, Removing
Special tools, testers and auxiliary items required
• Lifting tackle (VAS 3033)
• Drip tray (V.A.G 1306)
• Engine and Transmission Holder (VAS 6095)
• Shop crane (VAS 6100)
• Scissor lift table (VAS 6131)
• Engine/transmission jack (V.A.G 1383 A)
• Left subframe mounting (VAS 6131/6-1)
• Right subframe mounting (VAS 6131/6-2)
• Left suspension support (VAS 6131/6-3)
• Right suspension support (VAS 6131/6-4)
• Supports (Qty. 2) (VAS 6131/6-5)
• Supports (Qty. 2) (VAS 6131/6-6)
• Brace (VAS 6131/8)
• Step ladder (VAS 5085)
• Torque wrench (5 to 50 Nm) (V.A.G 1331)
The engine with transmission is removed downward.
- Check DTC memories of all control modules, before removing engine: --> VAS 5051 Vehicle Diagnostic, Testing and Information System; Guided Fault Finding; Vehicle System Test or VAS 5052; Vehicle Self-Diagnosis
• To allow free rotation of the drive axle, move the selector lever in the "N" position.
• Leave key in the ignition lock to prevent the steering wheel lock from engaging.
• It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover plates of the brake discs are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment.
• When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing engine.
• To prevent damage to the removed components, use the container for removed parts (V.A.G 1698) as storage.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
Disconnecting batteries
The procedure must be strictly followed!
- Switch off ignition and all electrical consumers.
- First, disconnect battery under driver's seat.
Work procedure
- Remove left and right wiper arms: -
- Pull engine compartment cover seal off bulkhead.
- Remove covers - A -, - B - and - C - in engine compartment.
CAUTION!
Fuel supply lines are under pressure! Wear protective eye wear and gloves to prevent injury and skin contact. Before loosening the hose connections, place a rag around the connection point. Then release pressure by carefully pulling hose off connection.
- Place a rag around connection to catch escaping fuel.
- Disconnect fuel supply line - arrow -.
- Disconnect breather line - arrow - to solenoid valve in engine compartment.
- Disconnect small connector - A - from engine control module (ECM) - 1 - and disconnect Ground (GND) connection - arrow - of wiring harness.
- Open fuse box cover on left in plenum chamber and disconnect connectors - A -, - B - and - C -.
- Remove wiring harness from plenum chamber and set it on the engine.
- Disconnect starter wire - 1 - and lay it aside on the engine.
- Disconnect connector from left mass air flow (MAF) sensor, and remove intake hose and left air filter housing.
- Disconnect connectors - 1 - through - 4 - for oxygen sensors and lay connectors aside on the engine.
• Connector for cylinder bank 1 = Black, Connector for cylinder bank 2 = Brown
- Remove right intake hose to throttle valve control module.
- Pull intake hose to Secondary Air Injection (AIR) Pump Motor (V101) off from upper part of air filter and remove upper part of air filter.
- Remove air filter element.
- Then pull off connecting wire - arrow - to compressor for air suspension on right of air filter housing --> [ Air Suspension Compressor Connection, Separating ] Air Suspension Compressor Connection, Separating
- Unclip transmission breather line from air filter housing.
- Remove bracket for right engine cover --> [ Removing bracket for right engine cover ] Service and Repair
- Pull lower part of air filter off to the right from air duct --> [ (Item 10) Air duct ] Service and Repair and remove it.
- Extract refrigerant from air conditioning system:
- Remove sound insulation tray.
- Loosen double pipe clamp between catalytic converter / center muffler and push clamp forward.
- Support exhaust system between rear muffler and center muffler using Engine/transmission jack (V.A.G 1383 A), remove mountings and lower exhaust system.
- Remove drive shaft tube.
- Remove front wheels.
- Remove front wheel housing liners.
- Separate hose connection to vacuum reservoir, in front of the left wheel housing.
- Remove heat shield - A - on steering gear and loosen universal joint - B -. --> Suspension, Wheels, Steering 48 Description and Operation
- Separate connectors - A - on transmission as well as transfer case - B - and loosen selector lever cable.
- Disconnect brake lines in wheel housing at brake hose and catch the brake fluid which runs out. --> Brake System 46 Removal and Installation
- In wheel housings, separate all connectors between body and front axle.
- Remove connection lines for air suspension at strut.
- Remove transmission transverse support - A -.
CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover cap with a rag and open carefully.
- Open and close cap on expansion tank, to relieve cooling system pressure.
- Drain coolant --> [ Cooling System, Draining and Filling ] Procedures.
- From the area of the left wheel housing, separate hose connections to heater core and catch escaping coolant.
- Pull upper coolant hose off radiator, and lower coolant hose off coolant pipe.
- Disconnect lines - arrow - from transmission oil cooler at lower right. Catch fluid which runs out.
- Disconnect line from power steering fluid cooler below on left. Catch fluid which runs out.
- Remove Ground (GND) wire - 1 - on long member at right front.
- Pull off coolant hose - 3 - and unfasten coolant pump with bracket - 2 -.
- Now remove one of rear mounting bolts - 3 -.
- Secure subframe to body --> Suspension, Wheels, Steering 40 Description and Operation
- Then proceed in exactly the same way with the other mounting bolt - 3 -.
- From the area of the plenum chamber, remove two least accessible bolts from suspension strut on each side of vehicle. --> Suspension, Wheels, Steering 40 Description and Operation
Preparing Scissor lift table (VAS 6131) for the continued work procedure:
- Mount front supports (VAS 6131/6-1) on left - 1 -, as well as (VAS 6131/6-2) on right - 2 - on lift table. The arrows on the supports indicate forward. Fasten bolts at the following positions: Left support - 1 -: A5, B4 and B5. Right support - 2 -: G4, H4 and H5
- Bolt both axle supports - 3 - (VAS 6131/6-3) and 6131/6-4 to lift table at following positions: Left axle support - 3 -: A6 and C6. Right axle support - 3 -: F6 and H6
- Rotate turntables of axle supports downward.
- Place supports - 4 - VAS 6131/6-5 for subframe and - 5 - VAS 6131/6-6 for transmission plate in corresponding positions on the lift table.
- Move horizontally aligned lift table under powertrain aggregate. The supports - 1 - must be guided into corresponding mount - arrow - at right and left.
- Simultaneously, guide right and left supports for transmission plate into corresponding holes - arrow -. When all four supports are in the appropriate receptacle holes without pressure:
- Extend both turntables of axle supports with slight preloading under control arms.
- Guide support - 2 - into corresponding mount in subframe, if necessary check support height on knurled nut.
- Loosen subframe bolts - 1 - and - 2 -, as well as transmission transverse support - 4 -.
- Use step ladder (VAS 5085) and remove respective third bolt of the suspension strut.
- Slowly lower engine/transmission assembly, constantly observing clearance.
Work procedure
- Support transmission using (VAS 6131/7-6) on lift table.
- Remove one of the lower bolts that fastens the transmission.
- From engine side, insert angled guide pin from (VAS 6131/8) into threaded hole.
- Fasten supports, positioned free of stress, to the table.
- Now, remove all bolts used for fastening transmission.
• To separate engine and transmission: --> Operating instructions for scissor lift table VAS 6131