Engine Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Lifting tackle (3033)
• Engine and transmission holder (VAS 6095)
• Engine and transmission jack (VAG 1383 A)
• Drip tray (VAG 1306)
• Shop crane (VAS 6100)
• Scissor lift table (VAS 6131)
• Spring type clip pliers (VAS 6340)
• Adapter (VAG 1318/20)
• Adapter (VAG 1318/20-1)
• Parts trolley (VAG 1698)
• 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 (VAS 6131/6-5) (Qty. 2)
• Supports (VAS 6131/6-6) (Qty. 2)
• Transmission support (VAS 6131/6-7)
• V6 engine support (VAS 6131/7)
• Cable tie
Procedure
The engine and transmission is removed downward.
• To allow free rotation of the driveshaft, move the selector lever in the "N" position.
• Leave the vehicle key in the ignition lock to prevent the steering wheel lock from locking.
• It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the backing 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.
• To prevent damage to the removed components, use the parts trolley (VAG 1698) for storage.
• When the engine is 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.
- Check Diagnostic Trouble Code (DTC) memories of all control modules, before removing engine.
Disconnect the Battery
The procedure must be strictly followed!
- Turn off the ignition and all electrical components.
- Disconnect battery under driver's seat.
Procedure
- Remove front wheels and tires.
- Remove windshield wiper arms.
- Remove plenum chamber cover.
- Pull engine compartment cover seal off bulkhead.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
- Remove covers - D -.
- Disconnect small connector - A - off engine control module and disconnect ground connection - arrow - of wiring harness.
- Open fuse box cover on the left side plenum chamber and separate connectors - A -, - B - and - C -.
- Remove wiring harness from plenum chamber and place it on engine.
- Disconnect starter wire - A - and generator wire - B - and place them on engine.
CAUTION!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting hose connection wrap a cloth around the connection. Then release pressure by carefully opening fuel line.
- Place a cloth around the connection to catch draining fuel.
- Disconnect fuel supply line - arrow -.
- Remove the vacuum hoses - 1 through 4 - from the intake manifold.
- Remove intake hose from the Mass Air Flow (MAF) sensor (G70) and the throttle valve control module (J338).
- Remove the throttle valve control module (J338). Refer to --> [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.
- Disconnect the oxygen sensor connectors - 1 through 4 - and lay them on the engine.
• Cylinders 1 through 3 = black
• Cylinders 4 through 6 = brown
- Separate the connecting line to the air suspension compressor at the air filter housing - arrow - as follows:
- Carefully pry off the green circlip - 1 - using a screwdriver. Then press the clamping ring - 2 - in direction of - arrow -.
- Pull only the slackened line - B - from the connection - A - at the air filter housing.
- Now remove the air filter housing upper part with MAF sensor (G70). Refer to --> [ Air Filter Assembly Overview ] Service and Repair.
- Unclip transmission breather line from air filter housing.
- Evacuate refrigerant circuit.
- Remove noise insulation tray.
- Remove heat shield at steering column to gear connection and loosen universal joint.
- Unclip selector lever cable.
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 cloth and open carefully.
- Drain the cooling system. Refer to --> [ Draining and Filling ] Procedures.
- Remove the upper coolant hose off the radiator, and lower coolant hose off the coolant pipe.
• Observe disposal regulations!
- Disconnect lines - arrow - from transmission oil cooler at lower right. Catch any fluid which drips out.
- Disconnect line from power steering fluid cooler below on left. Catch any fluid which drips out.
- Now remove mount from catalytic converter on vehicle floor.
- Loosen double clamp between catalytic converter and center muffler and slide back to center muffler.
Center muffler can remain installed.
- Disconnect connectors - A - at transmission and transfer case - B -.
- Remove driveshaft.
- Remove front wheel housing liners.
- In wheel housings, separate all connectors between body and front axle.
- Loosen brake line bracket and remove brake carrier from wheel bearing housing.
- Secure brake caliper with wire in wheel housing without bending brake lines.
- Remove right and left lower bolts - 2 - on stabilizer bar.
- Remove transmission carrier - A -.
- Remove ground (GND) wire on front right longitudinal member.
- Now remove one of the rear subframe bolts - 3 -.
- Secure subframe to body.
- Then proceed in exactly the same way with the other subframe bolts - 3 -.
Preparing Scissor Lift Table (VAS 6131) :
- Mount the front supports (VAS 6131/6-1) on the left - 1 -, as well as (VAS 6131/6-2) on the right - 2 - of the lift table. The arrows on the supports indicate forward position. Fasten the bolts at the following positions: Left support - 1 -: A5, B4 and B5. Right support - 2 -: G4, H4 and H5
- Bolt both axle supports (VAS 6131/6-3) and (VAS 6131/6-4) - 3 - to the lift table at the following positions: Left axle support: A6 and C6. Right axle support: F6 and H6
- Turn the turntables of the axle supports in.
- Place supports (VAS 6131/6-5) - 4 - for the subframe and (VAS 6131/6-6)- 5 - for the transmission bracket in the corresponding positions on the lift table.
- Move the horizontally aligned lift table under the powertrain assembly. The supports - 1 - must be guided into the corresponding mounts - arrow - on the right and left.
- Simultaneously, guide the right and left supports for the rear transmission bracket into the corresponding holes - arrow -. When all four supports are in the appropriate holes without pressure:
- Guide support - 2 - into corresponding mount in subframe, if necessary check support height on knurled nut.
- Raise both turntables of the axle supports with slight preloading under control arms.
- Now remove the lower bolt - 1 - on the right and left struts.
- Then remove right and left upper control arms from wheel bearing housing.
- Loosen subframe bolts - 1 - and - 2 -, as well as transmission carrier- 4 -.
- Slowly lower engine/transmission assembly, constantly observing clearance.
- Now install a bolt/nut on the left and right side from the subframe fastener through empty bore - arrow - and tighten engine carrier to subframe. This prevents engine carrier from slipping.
