Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Engine Support (T40074)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Spring Type Clip Pliers (VAS 5024 A)
• Engine and Transmission Holder (VAS 6095)
• Engine Support (3269)
• Shop Crane (VAS 6100)
• Drip Tray for VAS 6100 (VAS 6208) or Drip Tray (V.A.G 1306)
• Parts Trolley (V.A.G 1698)
• Engine Bung Set (VAS 6122)
• Cable tie
The engine with transmission is removed downward.
- Check the Diagnostic Trouble Code (DTC) memories for all the control modules. Refer to the vehicle diagnostic tester.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
• Leave the key in the ignition to prevent the steering lock from engaging.
• It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the brake disc cover plates are just above the floor. This enables the most ergonomic work position 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 engine.
• To prevent damage to the removed components, use (V.A.G 1698) for storage.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Make sure the wires have enough clearance to all moving or hot components.
Disconnect battery Ground (GND) cable with the ignition turned off.
- Remove the air filter housing with connecting hose to the throttle valve control module (J338). Refer to => [ Air Filter Housing Overview ] One Piece Intake Manifold.
- Remove the air filter housing bracket. Refer to => [ Air Filter Housing Overview ] One Piece Intake Manifold.
- Remove the windshield wiper arms and plenum chamber cover.
With Engine Control Module (ECM) with Anti-Theft Immobilizer
- Remove the locking plate or locking bracket from the ECM. Refer to => [ Engine Control Module ] Service and Repair.
Continuation for All Vehicles
- Disconnect the engine wiring harness connector from the ECM.
- Release the pass through for the engine wiring harness - arrow - and pull off upward.
- Remove the nut and generator wire - arrow - from the fuse holder.
- Remove he bolt and ground wire - arrow - from the longitudinal member.
- Open the cable guide locking mechanisms - arrows - on the longitudinal member.
- Disconnect all harness connectors for the engine wiring harness/body and set down the engine wiring harness on the engine.
- Disconnect the oxygen sensor connectors - 1 through 4 - at the bulkhead and free up the wires:
1 Heated Oxygen Sensor (HO2S) (G39), 6 pin connector (black)
2 Heated Oxygen Sensor (HO2S) Behind Three Way Catalytic Converter (TWC) (G130), 4 pin connector (black)
3 HO2S 2 (G108), 6 pin connector (brown)
4 HO2S 2 Behind TWC (G131), 4 pin connector (brown)
• On vehicles with All Wheel Drive (AWD), the connectors on the HO2S behind TWC - 2 - and HO2S 2 behind TWC - 4 - are secured on the underbody.
- Disconnect all connectors from the transmission.
- Remove all necessary remaining electrical wires from the engine/transmission and set aside.
- Remove the selector lever cable - 1 - from the selector shaft. Then remove the selector lever cable from the bracket - 2 -.
CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting to connection, wrap a cloth around the connection. Carefully release the pressure by loosening the connection.
- Disconnect the ventilation line - 1 -, the vacuum line - 2 - and the fuel supply line - 3 -. Press the release buttons to do this.
- Disconnect the vacuum line at brake booster.
- Disconnect all other connections, including vacuum and intake hoses from the engine.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply.
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.
- Open and close the expansion tank cap, to relieve the cooling system pressure.
- Remove the fan shroud with fans. Refer to => [ Fan Shroud with Fans ] Service and Repair.
- Remove the lower sections of the front wheel housing liners.
- Disconnect the connector from the oil level thermal sensor (G266).
- Disconnect the wire bracket for the oil level thermal sensor from the subframe.
• To prevent damage to the Air Conditioning (A/C) condenser and the refrigerant lines and hoses, do not stretch, kink or bend the pipes and hoses.
In order to remove and install the engine without opening the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the A/C compressor from the accessory bracket.
- Secure the A/C compressor to the lock carrier so that the refrigerant lines/hoses are not burdened.
- Remove the right drive axle shield.
- Remove the drive axles.
With All Wheel Drive (AWD)
- Remove the driveshaft flexible disc from the transmission.
Continuation for All Vehicles
- Remove the front exhaust pipes with the catalytic converters:
AWD, refer to => [ Front Exhaust Pipes with Catalytic Converters and Front Mufflers ] Front Exhaust Pipes With Catalytic Converters and Front Mufflers.
Front Wheel Drive (FWD), refer to => [ Front Exhaust Pipes with Catalytic Converters and Front Mufflers ] Front Exhaust Pipes With Catalytic Converters and Front Mufflers.
• Do not bend the decoupling elements of the exhaust pipes more than 20° or they could be damaged. Two technicians are needed to perform the removing procedure.
- Remove the pendulum support bolts - 1 through 3 - and remove the pendulum support.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Disconnect the coolant hoses from the radiator and engine using (VAS 5024A).
- Disconnect transmission fluid cooler line bolt - arrow - from the transmission. Catch any leaking transmission fluid.
- Install the (T40074) to the (V.A.G 1383 A).
- Remove the (T40074/1) from the (T40074) and install it to the cylinder block with a nut - 1 -.
- Position the (T40074) to the engine as shown and install the (T40074/1) to the (T40074) - 2 -.
- Tighten the (T40074) to the exhaust side of the cylinder block with 2 M10 x 25 bolts - arrows - as shown and tighten them to approximately 20 Nm.
- Gently lift the engine and transmission using (V.A.G 1383 A).
- Disconnect the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows - from above.
• Use (VAS 5085) to remove the bolts.
• Carefully guide the engine with transmission, when lowering, to prevent damage to the body.
- Carefully lower the engine with transmission.