Engine, Removing
Engine, Removing
• If the engine oil must be drained because of work performed on the removed engine, it should be drained with the engine installed. If the engine hangs on the engine lateral bracket (T03001) , the engine is not in its installed position and less engine oil will drain out.
Special tools, testers and auxiliary items required
• Hose Clip Pliers (VAS 6340)
• Hose Clip Pliers (VAS 6362)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Tensioning Strap (T10038)
• Step Ladder (VAS 5085)
• Engine Holder Bracket (T03000)
• Cable Ties
• Foam Mat
For information on securing the engine to the engine stand, refer to => [ Engine, Securing to the ] Service and Repair.
• To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.
• 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.
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.
• 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.
- Remove the cover - 1 - for the E-box and remove the wire - 2 -.
- Remove the battery tray bolts - arrows - and remove the battery tray from the vehicle.
- Disconnect the engine wiring harness connector from the Engine Control Module (ECM).
- Release the pass-through for the engine wiring harness - arrow - and pull off upward.
- Open locking mechanisms - arrows - on the wire guide on the longitudinal member.
- 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 -.
With a Automatic Transmission
- Disconnect the 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 bolts - arrows - and cylinder, set it aside, do not open line system.
Do not press the clutch pedal after removing the slave cylinder. The slave cylinder may be damaged by doing this.
- Disconnect the connector for the backup light switch on the transmission.
Continuation for All
- Disconnect the vacuum hose from the brake booster.
- Disconnect the connector from the heated oxygen sensor (G39) on the bulkhead and free up the electric wiring harness.
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 => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the front section of the right wheel housing liner..
- Move the lock carrier into the service position. Procedures
So that it is possible to remove the engine without opening the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Unbolt the Air Conditioning (A/C) compressor from the accessory bracket.
• To prevent damage to the A/C condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Tie up the A/C compressor with the refrigerant hoses still connected.
- Disconnect the connection from the generator and free up the wiring harness.
- Remove the 4 exhaust pipe with catalytic converter to exhaust manifold nuts - 2 - and the suspended mount bolts - 3 -.
- Remove the exhaust pipe with catalytic converter - 1 - from the manifold and tie up firmly to the side. Refer to => [ Exhaust Pipe with Catalytic Converter ] Exhaust Pipe With Catalytic Converter.
• The coupling element in the exhaust pipe with catalytic converter must not be bent more than 10°, otherwise it may be damaged.
- Remove the right drive axle and remove the left drive axle from the transmission.
- Remove the pendulum support.
• The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the fuel lines, place a cloth around the connection point. Remove the hose connection carefully to release the pressure.
- Disconnect the ventilation line - 1 -, vacuum line - 2 - and fuel supply line - 3 -. Press in the securing ring to disengage the lines.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the bolt - 2 - and move the windshield washer fluid reservoir - 1 - toward the front.
- Remove the bolts - 6 - and disconnect the connector - 3 -.
- Remove the bolts - 5 - and place the coolant expansion tank - 4 - on top of the engine with the hoses connected.
• Slightly loosen the bolts on the engine and transmission mounts before lifting the vehicle.
- Disconnect the coolant lines at the radiator and heater core (quick acting couplings).
- Install the engine holder bracket (T03000) as follows:
• Remove the pin (T03000/3) from the bracket.
• Mount the engine holder bracket (T03000) with the pin (T03000/4) to the cylinder block and tighten the bolts - 1 and 2 - hand tight.
• Then, install the pin (T03000/3) and tighten it to 20 Nm.
• Then, 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 lift the engine/transmission assembly slightly.
- Remove the engine mount from above. To do this, remove the bolts - 1, 2 and 3 -.
• Remove the rear bolt - 2 - through a hole in the wheel housing.
- Remove the transmission mount to transmission mount bracket bolts - arrows - from above.
• Use the step ladder (VAS 5085) to remove the mount bolts.
• The engine/transmission assembly must be guided with care to prevent damage while lowering it.
- Lower the engine/transmission assembly carefully downward.