Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Torque wrench 5-50 Nm (VAG 1331)
• Torque wrench 40-200 Nm (VAG 1332)
• Engine and transmission jack (VAG 1383A)
• Spring type clip pliers (VAS 5024A)
• Step ladder (VAS 5085)
• Engine holder bracket (T03000)
• Tensioning strap (T10038)
• Cable tie
• Foam mat
• If the engine oil must be drained because of work performed on the removed engine, it should be performed with the engine installed. If engine hangs on the engine lateral bracket (T03001), engine is not in installation position and less engine oil flows out.
Securing the engine to the engine stand. Refer to --> [ Engine, Securing to Assembly Stand ] Engine, Securing to Assembly Stand.
• To perform the work sequence, the ground cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut open when removing the engine, must be replaced in the same position when installing the 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. 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.
- Remove the engine cover with air filter. Refer to --> [ Engine Cover with Air Filter ] Engine Cover with Air Filter.
- Remove the battery..
- Open the cover - 1 - of the E-box and remove the wire - 2 -.
- Remove the bolts - arrows - and remove the battery holder from the vehicle.
- Disconnect the engine wiring harness electrical connector from the Engine Control Module (ECM). Refer to --> [ Removal and Installation ] Service and Repair.
- Release the pass through for the engine wiring harness - arrow - and remove upward.
- Open the locking mechanisms of the cable guides - arrows - on the longitudinal member.
- Disconnect the harness electrical connector - 4 -, open the locking mechanism and set down the engine wiring harness - 3 - on the engine.
- Remove the nut - 1 - and disconnect the ground wire and starter connections - 2 - and - 5 -.
With a Automatic Transmission
- Disconnect the electrical connector - 6 - from the multifunction switch.
- Remove the selector lever cable from the transmission.
With a Manual Transmission
- Remove the shift mechanism from the transmission..
- Remove the brace - 1 -.
- Remove the slave cylinder - arrows - and set aside, do not open the hydraulic system.
CAUTION!
Do not operate the clutch pedal anymore after the slave cylinder has been removed. Slave cylinder may be damaged by doing this.
- Disconnect the electrical connector for the backup lamp switch from the transmission.
Continuation for All
- Disconnect the vacuum hose from the brake booster.
- Disconnect the harness electrical connector for the Heated Oxygen Sensor (HO2S) on the bulkhead and free up the wiring harness.
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 cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Remove the front and rear sections of the right front wheel housing liner.
To facilitate removal and installation of the engine without having to open the refrigerant circuit, perform the following:
- Remove the ribbed belt. Refer to --> [ Ribbed Belt ] Ribbed Belt.
- Remove the Air Conditioning (A/C) compressor from the bracket. Refer to --> Heating, Ventilation and Air Conditioning.
• To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
• Also make sure the bumper cover is not damaged.
- Secure the A/C compressor on the bumper cover as shown using the (T10038) and a cloth - A -. Slide the (T10038) as far as possible onto the bolt - arrow -.
- Disconnect the electrical connector from the generator and free up the wiring harness.
- Remove the 4 nuts - 2 - and bolts - 3 -.
- Remove the front exhaust pipe - 1 - from the exhaust manifold and tie up off to the side. Refer to --> [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe with Catalytic Converter.
• The flex joint in the front exhaust pipe must not be bent more than 10 degrees, otherwise it may be damaged.
- Remove the right drive axle and remove the left drive axle from the transmission.
- Remove the subframe..
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before separating connection wrap a cloth around the connection to catch any leaking fuel. Then release pressure by carefully separating the connection.
- Disconnect the vent line - 1 -, the vacuum line - 2 - and the fuel supply line - 3 -. Press in the securing ring to disengage the lines.
- Seal the lines so that the fuel system is not contaminated.
- Remove the bolt - 2 - and place the windshield washer reservoir - 1 - toward the front.
- Remove the bolts - 6 - and disconnect the electrical connector - 3 -.
- Remove the bolts - 5 - and place the coolant expansion tank - 4 - with connected hoses onto the engine.
- Disconnect the coolant lines from the radiator and heater core (quick acting couplings).
- Install the (T03000) as follows:
• Remove pin (T03000/1) from the (T03000).
• Attach the (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 the (VAG 1383A) on the (T03000) and lift the engine/transmission assembly slightly.
- Remove the engine mount from above. To do so, remove bolts - 1 -, - 2 - and - 3 -.
The rear bolt to the cylinder block is accessible above wheel housing liner.
- Remove the bolts - arrows - for the transmission mount from above.
• Use the (VAS 5085) to remove the bolts.
• Engine/transmission assembly must be guided with care to prevent damage while lowering.
- Lower the engine/transmission assembly carefully downward.