Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Spring Type Clip Pliers (VAS 5024 A)
• Step Ladder (VAS 5085)
• Engine Holder Bracket (T03000)
• Tensioning Strap (T10038)
• Guide Pins (T10093)
• Adapter (T10467)
• Cable Ties
• Foam Mat
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
• Seal the disconnected fuel and ventilation lines to prevent dirt from getting into the systems.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
• If the engine oil must be drained because of work performed on the removed engine, it should be drained when he engine is still installed. If the engine hangs on the engine holder bracket (T03000) , the engine is not in its installed position and less engine oil will drain out.
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 fluid and vacuum) and electrical wiring 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.
- Check the Diagnostic Trouble Code (DTC) memories for all control modules. Refer to the vehicle diagnostic tester.
- Remove the air filter with engine cover. Refer to => [ Air Filter and Engine Cover ] Air Filter and Engine Cover.
- Remove the intake hose - 4 - between the throttle valve control module (J338) and air filter housing. To do so, disconnect the hose - 1 -, if present, and the hose - 2 - (compress the securing ring) and remove the spring clamp - 3 -.
- Remove the intake air scoop bolts - arrows - and air scoop from the lock carrier.
- Remove the E-box cover inside the engine compartment - arrows -.
Vehicles with an Automatic Transmission
- Unclip the Transmission Control Module (TCM) - 3 - from the bracket - 7 - and remove it upward.
- Disconnect the connector - 2 - from the TCM.
Continuation for all Vehicles
- Remove the bolts - 1 and 6 -.
- Move the bracket - 7 - with the power steering fluid reservoir to the side.
The hoses remain connected.
- Disconnect the line - 5 - and free it up.
- Disconnect the connector - 4 - from the Engine Control Module (ECM) and free up the engine wiring harness. Refer to => [ Motronic Engine Control Module (J220) ] Service and Repair.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Disconnect the connector - 4 -, open the locking mechanism and lay the engine wiring harness - 3 - on the engine.
- Disconnect the ground cable - 1 - and the starter connections - 2 and 5 -.
Vehicles with an Automatic Transmission
- Disconnect the connector - 6 - from the multifunction transmission range switch.
- Remove the selector lever cable from the transmission.
Vehicles with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Remove the brace bolts and the brace - 1 -.
- Remove the slave cylinder bolts - arrows - and set the cylinder aside, do not open the hydraulic system.
Do not operate the clutch pedal anymore after the slave cylinder has been removed. The slave cylinder may be damaged by doing this.
- Disconnect connector for the backup lamp switch from transmission.
Continuation for all Vehicles
- Disconnect the vacuum hose from the brake booster.
- Disconnect the connector from the heated oxygen sensor (G39) on the bulkhead. Move the wiring harness to the side.
- Open the cap on the coolant expansion tank and then close it again to release the pressure in the coolant system.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
• The vehicle has a manual hood support that is attached to the lock carrier.
- Move the lock carrier to the service position. Procedures
- Remove the fan shroud. Refer to => [ Fan Shroud and Fans ] Fan Shroud and Fans.
To facilitate removal and installation of the engine without having to open the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belts ] Ribbed Belts.
Refrigerant can cause serious personal injury.
• Do not open the Air Conditioning (A/C) refrigerant circuit.
- Remove the A/C compressor from the accessory bracket.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend the refrigerant lines and hoses.
- Secure the A/C compressor using a tensioning strap (T10038) and a suitable foam mat onto the right longitudinal member.
- Remove the clamps - arrows - for the power steering pressure line from the transmission.
- Remove the nuts - 1 - and the power steering pump hose.
- If the vehicle has an engine pre-heater, remove the cable - 2 -.
- Remove power steering pump from the accessory bracket and set it down at the front.
• The power steering lines remain connected to the power steering pump.
- Remove the four front exhaust pipe to exhaust manifold nuts - 2 - and the suspended mount bolts - 3 - from the subframe.
- Remove the front exhaust pipe - 1 - from the exhaust manifold and tie it to the side. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe with Catalytic Converter.
Danger of causing damage to the coupling element.
• Do not bend the coupling element more than 10°.
• Do not stretch the coupling element.
• Do not damage the wire mesh on the coupling element.
- Remove the right drive axle.
- Remove the left drive axle.
The fuel lines are under pressure.
Danger of personal injury to eyes and skin.
Wear protective goggles and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.
- Disconnect the fuel supply line - 1 - and the vent line - 2 -.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the coolant hoses - arrows - from the heater core.
- Open the spring clamps - arrows - and remove the coolant hoses from the radiator.
- Remove the bolt - 2 - and move the windshield washer filler tube - 1 - forward.
- Disconnect the connector - 3 -.
- Remove the bolts - 5 - and place the coolant expansion tank - 4 - on top of the engine with the hoses connected.
• Loosen the bolts on the engine and transmission mounts one turn.
- Install the engine holder bracket (T03000) as follows:
• Remove the pin (T03000/1) from the engine holder bracket (T03000).
• Install the engine holder bracket (T03000) to the cylinder block with the pin - 3 - and tighten the bolts - 1 and 2 - hand tight.
• Tighten the pin (T03000/1) to 20 Nm.
• Tighten the bolts - 1 and 2 - to 25 Nm.
- Place the engine-/gearbox jack (V.A.G 1383 A) under the engine holder bracket (T03000) and raise the engine/transmission subassembly slightly.
Use a step ladder (VAS 5085) to remove the bolts from the engine/transmission mount.
- Remove the engine mount from above. To do so, remove the bolts - 1, 2 and 3 -.
• The single bolt - 2 - is accessible through a hole in the wheel housing.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• Verify that all hoses and lines between the engine/transmission subassembly and body have been disconnected.
• A 2nd technician is needed to lower the engine/transmission subassembly.
• The engine/transmission subassembly must be guided with care to prevent damage while lowering.
- Carefully lower the engine/transmission subassembly. When doing this, rotate or push the engine/transmission subassembly.