Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Lifting tackle (3033)
• Engine support (T40074)
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Engine and transmission jack (VAG 1383A)
• Step ladder (VAS 5085)
• Spring type clip pliers (VAS 5024A)
• Engine and transmission holder (VAS 6095) with engine support (3269)
• Shop crane (VAS 6100)
• Drip tray (VAG 1306) or drip tray for VAS 6100 (VAS 6208)
• Parts trolley (VAG 1698)
• Engine bung set (VAS 6122)
The engine and transmission are removed downward.
- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Refer to ; "Guided Fault Finding ".
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same location when installing the engine.
• Leave the vehicle key in the ignition to prevent the steering wheel lock from locking.
• It is advisable to remove the front wheels before removing the engine/transmission. The vehicle can be lowered on the hoist until the cover plates for 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 the engine.
• To prevent damage to the removed components, use the (VAG 1698 ) for storage.
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 (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires 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.
- With the ignition off, disconnect the battery ground cable. Refer to.
- Completely remove the air filter and connecting hose. Refer to => [ Air Filter Assembly Overview ] Removal and Replacement.
- Remove the air filter bracket.
- Remove the windshield wiper arms and plenum chamber cover.
- Loosen the bolts - arrows - for the plenum chamber bulkhead - 1 - and remove it together with the resonance tube - 2 -.
- Remove the protective housing from the Engine Control Module (ECM). Refer to => [ Engine Control Module with Anti-Theft Immobilizer ] Engine Control Module with Anti-Theft Immobilizer.
- Disconnect the engine wiring harness electrical connector from the ECM.
- Release the pass through for the engine wiring harness - arrow - and pull off upward.
- Remove the nut - arrow - and remove the wire for the generator from the fuse holder.
- Remove the ground cable bolt - arrow - from the longitudinal member.
- Open the locking mechanisms - arrows - for the cable guide on the longitudinal member.
- Disconnect all harness connectors for the engine harness to the body harness and set the engine harness on the engine.
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.
- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect the fuel supply line - 4 - and catch any leaking fuel with a cloth.
- Disconnect the vent line - 2 - and vacuum line - 3 -.
• Press in the securing ring to disengage the fuel line.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Disconnect the Heated Oxygen Sensor (HO2S) electrical connectors - 1 and 2 - at the bulkhead and free up the wires.
1 HO2S 2, 6 pin connector (brown)
2 HO2S, 6 pin connector (black)
- Disconnect any remaining electrical wires from the engine/transmission and set aside.
- Remove the brake booster vacuum hose from the intake manifold.
- Disconnect all other connections - vacuum and intake hoses from the engine.
- Remove the shift mechanism from the transmission.
CAUTION!
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to your eyes and from scalding. Cover the cap with a cloth and open the cap very carefully.
- Open and close the cap on the expansion tank, to relieve the cooling system pressure.
- Remove the noise insulation.
- Remove the front sections of the wheel housing liners.
- Bring the lock carrier into the service position. Radiator Support
- Disconnect the wire bracket for the oil level thermal sensor at the subframe.
- Remove the front exhaust pipe with catalytic converters. Refer to => [ Front Exhaust Pipe with Catalytic Converters ] Front Exhaust Pipe with Catalytic Converters.
• Do not bend the flex joints in front of the exhaust pipes 20 degrees or they could be damaged. A second mechanic is required for the removal.
- Remove the front driveshaft tube.
• To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
To facilitate removal and installation of the engine without having to open the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Open the refrigerant line fasteners on the body.
- Remove the Air Conditioning (A/C) compressor with connected refrigerant lines from the accessory bracket.
- Disengage the A/C compressor - A - at the lock carrier as shown (fasteners - 1 and 2 -.
- Remove the right drive axle heat shield.
- Remove the drive axles.
- Remove the pendulum support bolts - 1 through 3 - and remove the pendulum support.
- Drain the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Disconnect the coolant hose quick release couplings from the radiator and heat exchanger.
- Remove coolant hoses to the expansion tank.
- Install the (T40074) to the (VAG 1383A ).
- Remove the (T40074/1) from the (T40074 ) and install it to the cylinder block using a nut - 1 -.
- Position the (T40074) on the engine as shown and install the (T40074/1) to the (T40074) - 2 -.
- Secure the (T40074) with M10 x 25 bolts - arrows - to the exhaust side of the cylinder block as shown and tighten to approximately 20 Nm.
- Gently lift the engine and transmission using the (VAG 1383A ).
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• Use the (VAS 5085) to remove the bolts.
• Carefully guide the engine and transmission, when lowering, to prevent damage to the body.
- Carefully lower the engine and transmission.