Engine, Removing
Engine, removing
Secure engine to engine stand.
Note:
^ To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.
^ The engine is removed downward together with the transmission.
^ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
^ To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
- Remove engine cover with air filter.
- Remove battery.
- Open cover - 1 - of E-box and remove wire - 2 -.
- Remove bolts - arrows - and remove battery holder from vehicle.
- Remove Engine Control Module (ECM).
- Release pass-through for engine wiring harness - arrow - and pull off upward.
- Open locking mechanisms of cable guide on longitudinal member - arrows -.
- Disconnect harness connector - 4 -, open locking mechanism and set down engine wiring harness - 3 - on engine.
- Disconnect Ground (GND) wire - 1 - and starter connections - 2 - and - 5 -.
Vehicles with automatic transmission
- Disconnect connector - 6 - from multi-function switch.
- Remove selector lever cable from transmission.
Vehicles with manual transmission
- Remove shift mechanism from transmission.
- Remove brace - 1 -.
- Remove slave cylinder - arrows - and set aside, do not open line system.
CAUTION!
Do not operate the clutch pedal anymore after slave cylinder has been removed. Slave cylinder may be damage by doing this.
- Disconnect connector for back-up light switch from transmission.
Continuation for all vehicles
- Disconnect vacuum hose from brake booster.
- Disconnect harness connector for Heated Oxygen Sensor (HO2S) G39 on bulkhead expose wiring harness.
CAUTION!
Hot steam may escape when opening expansion tank. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.
- Drain coolant.
- Remove front and rear sections of right front wheel housing liner.
To facilitate removal and installation of engine without having to open refrigerant circuit:
- Remove ribbed belt.
- Remove A/C compressor from bracket for assemblies.
Note:
^ To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
^ Also make sure bumper cover is not damaged.
- Secure A/C compressor on bumper cover as depicted using tensioning strap T10038 and a matching base - 1 -. Slide tensioning strap T10038 as far as possible on to mounting bolt - arrow -.
- Disconnect connection on generator and expose wiring harness.
- Remove 4 nuts - 2 - and bolts - 3 -.
- Remove front exhaust pipe - 1 - from manifold and tie up firmly to side.
Note:
^ Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Remove right drive axle and remove left drive axle at transmission.
- Remove subframe.
CAUTION!
^ Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around connection. Then release pressure by carefully pulling hose off connection.
- Disconnect vacuum line - 1 - (engines BGP and BGQ only), vent line - 2 - and fuel supply line - 3 -. Press in securing ring to disengage lines.
- Seal lines so that the fuel system is not contaminated by dirt etc.
- Remove bolt - 2 - and place windshield washer reservoir - 1 - toward front.
- Remove bolts - 6 - and disconnect connector - 3 -.
- Remove bolts - 5 - and set down coolant expansion tank - 4 - with connected hoses on to engine.
- Disconnect coolant lines on radiator and heater core (quick acting couplings).
- Install Engine Holder Bracket T03000 as follows:
^ Remove pin T03000/1 from Engine Holder Bracket T03000.
^ Attach Engine Holder Bracket T03000 to cylinder block with pin - 3 - and tighten bolts - 1 - and - 2 - hand-tight.
^ Then install pin T03000/1 and tighten to 20 Nm.
^ Then tighten bolts - 1 - and - 2 - to 25 Nm.
- Place Engine/transmission jack V.A.G 1383 A on Engine Holder Bracket T03000 and lift engine/transmission assembly slightly.
- Remove engine mount from above. To do so, remove bolts - 1 -, - 2 - and - 3 -.
- The rear bolt in cylinder block is accessible above wheel housing liner.
- Remove bolts - arrows - from transmission bracket from above.
Note:
^ Use step ladder VAS 5085 to remove mounting bolts.
^ Engine/transmission assembly must be guided with care to prevent damage to damage while lowering.
- Lower engine/transmission assembly carefully downward.