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-/Gearbox Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Hose Clip Pliers (VAS 6340)
• Spring Type Clip Pliers (VAS 6499)
• Engine and Transmission Holder (VAS 6095)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Drip Tray for VAS 6100 (VAS 6208)
• Engine Bung Set (VAS 6122)
• Container for Removed Parts (V.A.G 1698 A)
• Cable Ties
• High Temperature Grease (G 052 133 A2)
Procedure
• 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 performed 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.
• It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can then be lowered on the hoist until the cover plates for the brake discs 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. Determine which parts are faulty before removing so that they can be replaced while they are removed.
• Use the container for removed parts (V.A.G 1698) to store the removed parts so that they do not get damaged.
Note the following whenever working inside the engine compartment due to limited space:
• Route all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
- Check the Diagnostic Trouble code (DTC) memories of all control modules. Refer to the Vehicle Diagnostic Tester.
- Remove the complete air filter housing with the connecting pipe to the throttle valve control module. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Remove the air filter housing bracket. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Remove the E-box cover inside the engine compartment - arrows -.
Turn off the ignition and disconnect the battery ground cable.
- Disconnect the connector - 3 - from the Engine Control Module (ECM) and free up the electrical harness. Refer to => [ Engine Control Module, without Protective Housing ] Engine Control Module, without Protective Housing.
- Remove the nut - arrow - and the generator cable from the fuse panel.
- Disconnect the connector - 4 -, open the locking mechanism and lay the engine harness - 3 - on the engine.
- Disconnect the ground cable - 1 - and the starter connections - 2 and 5 -.
- Disconnect the heated oxygen sensor connectors at the bulkhead. Move the electrical harness to the side.
- Disconnect all connectors from the transmission.
- Disconnect all remaining electrical wires necessary, from the engine/transmission and set aside.
- Disconnect the selector lever cable from the transmission.
The fuel lines are under pressure.
Danger of personal injury to eyes and skin.
Wear protective eyewear 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 ventilation line - 2 -.
- Disconnect the vacuum line from the brake booster and intake manifold.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Follow the guidelines for clean working conditions. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
The coolant system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the cap on the coolant expansion tank and then close it again to release the pressure in the coolant system.
• The vehicle has a manual hood support that is attached to the lock carrier.
- Move the lock carrier into the service position. Procedures
- Remove the coolant fan shroud. Refer to => [ Fan Shroud ] Service and Repair.
- Remove the wheel housing liners..
- Disconnect the connector from the oil level thermal sensor.
- Remove the oil level thermal sensor wire holder from the subframe and lay it on the subframe.
- Remove the electrical wires from the bracket and remove the bracket nuts - arrows - (two M6 nuts) and bracket from the transmission front cover.
- Move the wires near the transmission front cover upward and secure them.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Remove the coolant hoses - arrows - from the heater core.
- Release the clip - arrow -.
- Remove the upper coolant hose - 1 - from the radiator.
- Remove the bolt - 2 - and move the windshield washer filler tube forward - 1 -.
- 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 for the engine and transmission mounts one turn.
Refrigerant can cause serious personal injury.
• Do not open the Air Conditioning (A/C) refrigerant circuit.
So that it is possible to remove the engine without opening the 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 to the bumper cover using a tensioning strap (T10038) and a suitable mat - A -. Slide the tensioning strap (T10038) as far as possible onto the bolt - arrow -.
- Remove the right drive axle heat shield bolts - arrow - and shield.
- Remove the both drive axles.
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 exhaust pipe with catalytic converter to exhaust manifold nuts - arrows -.
- Loosen the rear clamping sleeve and remove the suspended mount to subframe bolts. Remove the front exhaust pipe with the oxygen sensors.
• The oxygen sensors can remain installed.
- Remove the pendulum support bolts - 1 through 3 - and remove the pendulum support.
- Insert the engine support (T40074) onto the engine-/gearbox jack (V.A.G 1383 A).
- Remove the front adapter (T40074/1) from the engine support (T40074) and secure it to the cylinder block with a nut - 1 -.
- Position the engine support (T40074) under the engine as illustrated and install the front adapter (T40074/1) to the engine support (T40074) with the bolt - 2 -.
- Secure the engine support (T40074) to the exhaust side of the cylinder block with 2 M10 x 25 bolts - arrows - as illustrated, and tighten the bolts to approximately 20 Nm.
- Gently lift the engine and transmission using the engine-/gearbox jack (V.A.G 1383 A).
- Remove the engine mount to engine mount bracket bolts - arrows - from the top.
- Remove the transmission mount to transmission mount bracket bolts - arrows - from above.
• Use the step ladder (VAS 5085) to remove the engine/transmission mount bolts.
• Carefully guide the engine with transmission, when lowering it, in order to prevent damage to the body.
- Carefully lower the engine with transmission.