Engine Through 05.2010, Removing
Engine Through 05.2010, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor-Type Assembly Platform (VAS 6131 A) with Support Set (VAS 6131/10) as well as Supplementary Set (VAS 6131/11) , (VAS 6131/13) and qty. 3 (VAS 6131/10-2)
• Drip Tray (VAS 6208)
• Hose Clamps Up to 25 mm Dia. (3094)
• Hose Clip Pliers (VAS 6362)
• Ball Joint Puller (T10187)
Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• During installation, all cable ties must be installed at the same location.
• Collect escaping coolant in a clean container for disposal or reuse.
- On a vehicle with air suspension, activate vehicle lift mode.
• To rotate the driveshaft freely, move the selector lever into "N".
Danger of causing damage to electrical components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
• Pay attention the to waiting period for vehicles with urea injection.
- Disconnect the Ground (GND) cable - 4 -.
- Empty coolant circuit.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
- Open the coolant reservoir cap.
- Remove the left and right front wheels.
- Remove the noise insulation - 1 - and - 2 -..
- Remove left and right front wheel housing liners..
- Place (VAS 6208) under engine.
- Remove the coolant hose from the left coolant pipe by loosening the hose clamp - arrow - and letting the coolant drain out.
- Disconnect electrical connector - 2 - on engine coolant temperature (ECT) sensor on radiator (G83).
- Remove the right lower coolant hose from the radiator by lifting the clamp - 1 - and let the coolant drain out.
- Loosen the hose clamps, remove the coolant hoses from the heat exchanger - arrows - and let the coolant drain out.
- Remove the coolant hose from the right coolant pipe by loosening the hose clamp - arrow - and letting any remaining coolant drain out.
- Carefully pull the engine cover off the 4 bolts one after the other - arrows -.
- Pull the cover - arrows - over the radiator, to do this disconnect the lower coolant hose.
- Remove the coolant hose; to do this, loosen the hose clamp - 1 -.
• Ignore - 2 -.
Very hot fuel can burn your skin.
• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
• Wear protective gloves.
• Wear safety glasses.
- Remove the bolts - 1 - and - 2 - as well as the nut - 4 -.
- Move the fuel filter to the side, with the fuel hoses still connected - 3, 5 and 6 -.
- Remove the bolts - 1 through 4 - and move the fuel system cooler to the side.
• The fuel filter bracket remains in its installation position.
- Open the cover over the terminal 30 wire junction 2 (TV22) - arrow -.
- Remove the bolt - 1 - for the battery jump start terminal (U6) and free up the electrical wire.
- Remove the air guide hose by loosening the hose clamps - arrows -.
- Disconnect the connector - 3 -.
- Remove the bolts - 1 - and - 2 -, remove the throttle valve control module (J338) from the intake tube.
• Place a cloth underneath to soak up any escaping power steering fluid.
- Disconnect the power steering pump fluid line and the (3094).
- Loosen the hose clamp - 1 - and remove the power steering fluid hose.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Ignore - 2 -.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the clamp bolts - 1 - and - 5 -.
- Remove the bolts - 3 - and - 4 - and then remove the refrigerant lines from the A/C compressor.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Ignore - 2 -.
- Unclip the coolant hose on the air filter housing upper section.
- Unclip the front final drive vent hose - 1 - from the air filter housing.
- Disconnect the connector - 3 - from the Mass Airflow (MAF) sensor (G70).
- Remove the air duct hose form the turbocharger by loosening the hose clamps - 4 -.
- Unlock the clips - 2 -.
- On vehicles with air suspension, push the securing ring - 1 - forward off the hose coupling, press the release ring - 2 - downward - arrows - and remove the ventilation hose - 3 - from the air filter housing upper section.
- Remove the air filter housing upper section and the air filter.
- Pry off the air guide - 2 - from the air filter housing lower section - 1 - starting on the wheel housing side using the (80 - 200).
- Remove the bolts - 1 - and - 2 -.
- Remove the air filter housing lower section; to do this, slightly push on the windshield washer fluid reservoir to the side.
- Remove the air duct hoses by loosening the hose clamps - 1, 2 and 3 -.
- Disconnect electrical connector - arrow -.
- Disconnect the vacuum hose - arrow - leading to the brake booster.
Very hot fuel can burn your skin.
• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
• Wear protective gloves.
• Wear safety glasses.
There is a risk of injury because the fuel is under pressure.
• To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Disconnect the fuel supply line - 1 - and return line - 2 - on the bulkhead.
- Disconnect the Exhaust Gas Temperature (EGT) sensor 2 (G448) - 1 - and Heated Oxygen Sensor (HO2S) (G39) - 2 - connectors.
- Free up electrical wires.
• Ignore - 3 and 4 -.
- Remove the heated oxygen sensor (HO2S) - 5 -.
- Remove the NOX sensor (G295) - 4 - and free up the electrical wire.
- Secure the NOX sensor to the body.
• Ignore - 1, 2 and 3 -.
- Remove the windshield wiper arms - 1 - and - 3 -.
The plenum chamber cover could be damaged.
• Coat the transition area between the windshield and plenum chamber cover with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.
- Remove gasket - 5 -.
- Carefully remove the plenum chamber covers - 2 - and - 4 - from the retainers on the windshield.
- Remove cover for E-box, plenum chamber - arrows -.
- Disconnect the connectors - 1, 2 and 3 - at E-box plenum chamber coupling station and free up the wiring harness.
- Disconnect electrical connector - arrow -.
- Remove the ground (GND) connection nut - 2 -.
- Remove Engine Control Module (ECM) - 1 -.
- Free up electrical wiring harness to engine.
- Loosen upper control arm nut a few turns and pull joint off with the (T10187).
- Completely remove upper control arm nut.
- Repeat procedure on opposite side of vehicle.
- Disconnect the electrical connectors - arrow - at the left and right on the front speed sensors.
- Remove wiring harness bolts - arrows -.
- Remove brake caliper bolts - 1 -.
• Do not change brake line bent shape.
- Engage brake caliper in wheel housing with wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Repeat procedure on opposite side of vehicle.
- Disconnect lower threaded connection - 2 - at left and right on stabilizer bar.
- Remove nuts from bolts - 1 - at left and right on strut.
• Bolts - 1 - are removed later.
- Disconnect the exhaust system at the clamping sleeve - arrows -.
- Remove NOX sensor 2 (G687) - 3 -.
- Disconnect the connector - 5 - and free up the electrical wire.
- Loosen the clamp - arrow - and remove the reducing agent injector (N474).
- Move the nuts - 1 - and bolts - 2 - and - 4 - and remove the SCR catalytic converter.
- Remove the bolts - arrows - that attach the rear driveshaft to the transfer case.
- Slide rear driveshaft toward rear final drive; CV joints can move axially.
- Secure the driveshaft to the side.
- Remove the nuts and bolts - arrows - then remove the noise insulation bracket.
- Remove the exhaust system bracket bolts - arrows - on the longitudinal member.
- Remove the Exhaust gas temperature sensor 4 (G648) - arrow -.
- Remove the differential pressure sensor (G505) hoses from the pressure lines on the particulate filter; to do this, loosen the hose clamps - arrows -.
- Disconnect electrical connector - arrow - on steering gear.
- Remove the 2 bolts and then remove the steering gear heat shield - A -.
Risk of distorting airbag spiral spring.
• Separate universal joint from steering gear only when front wheels are in straight ahead position.
• Secure steering wheel with adhesive tape to prevent position of steering wheel and steering gear from changing.
- Remove the universal joint bolt - B -.
- Remove universal joint from steering gear.
- Place the (V.A.G 1782) under the disconnection point.
- Loosen the hose clamp - arrow - and disconnect the left fluid line on the lock carrier leading to the power steering cooler.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove the bolt - arrow -, free up the coolant hose and move the fuel cooler pump (V166) to the side.
• Observe the rules of cleanliness for working on automatic transmissions.
- Remove the bolt - arrow - and disconnect the ATF lines from the ATF thermostat.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove the nut - 1 - on the right longitudinal member and disconnect the Ground (GND) wire from the threaded pin.
- Disconnect the automatic transmission connectors - 1, 2 and 3 -.
Prepare Scissor Lift Platform:
- Equip scissor-type assembly platform (VAS 6131 A) with support set (VAS 6131/10) and supplementary set (VAS 6131/11) and (VAS 6131/13) as follows:
- First manually secure the mounting elements to the (VAS 6131 A).
- Position the scissor lift table horizontally.
• Note bubble level (sight glass) on support platform.
- Guide scissor lift table under the engine/transmission subassembly.
- Attach mounting elements from (VAS 6131/10) and (VAS 6131/11) at front of subframe as shown in illustration.
- Ensure threaded spindles are completely installed.
- Attach mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the left and right on the transmission carrier as shown in the illustration.
- Position mounting elements (VAS 6131/13) at the left and right on the suspension struts as shown in the illustration.
- Attach mounting elements from (VAS 6131/10) at the left and right on the subframe as shown in the illustration.
- Attach mounting elements from (VAS 6131/10) at left and right on transmission carrier as shown in illustration.
- Rotate mounting element spindles upward until all mounting pins come in contact with mounting points.
- Attach mounting element base plates to the (VAS 6131 A) and tighten to 20 Nm.
- Mark position of subframe, engine carrier and transmission carrier to longitudinal members with a felt-tip pen.
- Remove the bolts - 1 to 4 - in a diagonal sequence in steps.
Risk of damaging hose and wiring connections as well as engine compartment.
• Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
• Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.
• Carefully guide the suspension struts past the longitudinal members.
- Next lower engine/transmission subassembly with the (VAS 6131 A) only by dimension - a -.
• Dimension - a - = 20 centimeters (7.87 in.)
- Remove the bolts - 1 through 4 - and remove the selector lever cable heat shield.
- Remove the selector lever cable ball head - 2 - from the transmission shift lever using the (80 - 200).
- Remove securing clips - 1 - and remove selector lever cable from transmission.
• Do not bend or kink the selector lever cable.
- Lower the engine/transmission subassembly further.
- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.