Removing
Removing
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Engine and Transmission Holder (VAS 6095)
• Engine/Transmission Jack (V.A.G 1383A)
• Drip Tray (V.A.G 1306)
• Shop Crane (VAS 6100)
• Scissor Lift Table (VAS 6131)
• Hose Clip Pliers (VAS 6340)
• Adapter for K-jetronic Test Device (V.A.G 1318/20)
• Adapter (V.A.G 1318/20-1)
• Parts Trolley (V.A.G 1698)
• Left Subframe Mount (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) (Quantity: 2)
• Supports (VAS 6131/6-6) (Quantity: 2)
• Gearbox Support (VAS 6131/6-7)
• V6 Engine Support (VAS 6131/7)
• Cable Tie
The engine with transmission is removed downward.
• To allow free rotation of the driveshaft, move the selector lever into the "N" position.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
• It is advisable to remove the front wheels before removing the engine/transmission. The vehicle can then be lowered until the brake disc cover plates are just above the floor. This enables the most ergonomic work position possible regarding accessibility to components in the engine compartment.
• To prevent damage to the removed components, use the (V.A.G 1698) for storage.
• 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.
- Check the Diagnostic Trouble Code (DTC) memories of all control modules, before removing the engine. Refer to the vehicle diagnostic tester.
Battery, Disconnecting:
The procedure must be strictly followed!
- Turn off the ignition and all electrical components.
- First, disconnect the battery under the driver seat.
Removing
- Remove the front wheels.
- Remove the windshield wiper arms.
- Remove the plenum chamber cover.
- Remove the hood seal from the bulkhead.
- All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
- Remove the covers - D -.
- Disconnect the small connector - A - from the Engine Control Module (ECM) and disconnect the ground connection - arrow - for the wiring harness.
- Open the fuse box cover in the left plenum chamber and disconnect connectors - A, B and C -.
- Remove the wiring harness from the plenum chamber and place it on the engine.
- Remove the nuts and remove the starter wire - A - and generator wire - B - and place them on the engine.
CAUTION!
The fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then release pressure by carefully disconnecting the connection.
- Place a cloth around the connection to catch any leaking fuel.
- Disconnect the fuel supply line - arrow -.
- Disconnect the vacuum hoses from the intake manifold connections - 1 through 4 -.
- Remove the intake hose from the Mass Airflow (MAF) sensor (G70) and throttle valve control module (J338).
- Remove the throttle valve control module. Refer to => [ Intake Manifold Overview ] Intake Manifold Overview.
- Disconnect the oxygen sensor electrical connectors - 1 through 4 - and lay them on the engine.
• Cylinders 1 through 3 = black connectors
• Cylinders 4 through 6 = brown connectors
- Disconnect the line - arrow - for the air suspension compressor from the upper air filter housing as follows:
- Carefully pry off the green circlip - 1 - using a screwdriver. Then push the clamping ring - 2 - in the - direction of the arrow -.
- Pull the line - B - from the fitting - A - on the upper air filter housing.
- Remove the upper air filter housing with the MAF sensor. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Unclip the transmission ventilation line from the air filter housing.
- Evacuate the refrigerant from the Air Conditioning (A/C) system.
- Remove the noise insulation.
- Remove the heat shield from the steering gear and loosen the universal joint.
- Unclip the selector lever cable.
CAUTION!
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a cloth and open very carefully.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Remove the upper coolant hose from the radiator, and the lower coolant hose from the coolant pipe.
• Observe coolant disposal regulations!
- Remove the transmission oil cooler line bolt - arrow - and disconnect the lines. Catch any fluid which runs out.
- Disconnect the lines from the power steering fluid cooler. Catch fluid which runs out.
- Remove the suspended mount for the catalytic converters from the underbody.
- Loosen the double clamp between the catalytic converters and center muffler and slide back the center muffler.
The center muffler can remain installed.
- Disconnect the connectors - A - for the transmission and transfer case - B -.
- Remove the rear driveshaft.
- Remove the front wheel housing liners.
- In the wheel housings, disconnect all connectors between the body and front axle.
- Loosen the brake line bracket and remove the brake carrier from the wheel bearing housing.
- Secure the brake caliper (with wire ) in the wheel housing without bending the brake lines.
- Remove the right and left lower bolts/nuts - 2 - for the stabilizer bar.
- Remove the transmission transverse support - A -.
- Remove the Ground (GND) wire from the right front longitudinal member.
- Remove one of the rear bolts - 3 - for the subframe.
- Secure the subframe.
- Proceed in exactly the same way with the other rear bolt - 3 - for the subframe.
Preparing the (VAS 6131) for the continued work procedure:
- Install the front supports (VAS 6131/6-1)- 1 - on the left side and (VAS 6131/6-2)- 2 - on the right side of the (VAS 6131). The arrows on the supports point in the direction of travel. Install the bolts in the following positions: left support - 1 -: A5, B4 and B5; right support - 2 -: G4, H4 and H5
- Install both axle supports - 3 - (VAS 6131/6-3) and (VAS 6131/6-4) to the (VAS 6131) at the following points: left axle support - 3 -: A6 and C6; right axle support - 3 -: F6 and H6
- Turn the turntable pads on the axle supports downward.
- 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 (VAS 6131).
- Position the (VAS 6131) under the engine. 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 the support - 2 - into the corresponding mount in the subframe, if necessary check the support height on knurled nut.
- Extend both turntable pads on the axle supports with slight pre-loading under the control arms.
- Remove the lower bolts - 1 - from the right and left struts.
- Remove the upper right and left control arm bolts from the wheel bearing housing.
- Loosen the subframe bolts - 1 and 2 - and the transmission carrier bolts - 4 -.
- Slowly lower the engine/transmission, constantly observing clearance.
- Install a bolt with a nut - arrow - on the left and right sides of the subframe through the empty holes and secure the engine carrier to the subframe. This prevents the engine carrier from slipping.
