Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Drip Tray (VAS 6208)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Engine/Trans. Support (T10012)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Ring Spanner 7-Piece Set (3337)
• Locking Pin (T10060A)
• Puller (T10369)
• Engine Bung Set (VAS 6122)
Procedure
• Assemble engine with transmission downward.
• During installation, cable ties must be installed at the same location.
• Collect escaping coolant in a clean container for disposal or reuse.
There is a risk of injury because the fuel is under very high pressure.
• When removing the engine, the high pressure area of the fuel injection system is not opened.
• If the engine is removed and the high pressure area is opened for the following steps, the fuel pressure in the injection system must be reduced to a residual pressure before opening the high pressure area.
- Reduce fuel pressure in high pressure area. Refer to => [ Before Opening High Pressure Fuel Injection System ] Before Opening High Pressure Fuel Injection System.
Danger of causing damage to electrical components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Remove luggage compartment floor covering.
- If the battery negative post cover is under the rear cross panel trim, remove rear cross panel trim.
- Release retaining clips - arrows - and remove negative post cover.
- Loosen nut a few turns and remove terminal clamp - arrow - on the ground (GND) cable from battery post.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Reduce pressure by covering coolant reservoir cap with a cloth and carefully open.
- Open the coolant reservoir cap.
- Remove both front wheels.
- Remove the front noise insulation - 1 -.
- Remove left and right noise insulation - arrows -.
- Remove the noise insulation frame - arrow - and the rear noise insulation.
- Place the (VAS 6208) under the engine.
- Remove the lower coolant hose - arrow - from the radiator by lifting the clamp and let the coolant drain out.
- Remove lower coolant hose to after-run coolant pump (V51) - arrow - and allow coolant to drain.
- Remove the air guide hose by loosening hose clamps - 1 - and - 2 -.
- Disconnect the connector - 2 -.
- Remove the bolts - 3 -.
- Remove the engine cover - arrows -.
- Remove the coolant hoses - 1 - and - 2 -.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the protective boot - 2 - and disconnect the fuel hose by pressing the release ring.
- Remove the hose - 1 -.
- Release the EVAP canister - B arrow -, remove it upward - A arrow - and lay it aside.
- Remove the bolts - arrows - and air guide.
- Remove the bolts - 1 - and remove the fan shroud upward.
- Remove the upper coolant hose - arrow - from the radiator by removing the retaining clip.
- Remove the bolts - arrows - on the rear side of the radiator.
- Remove the radiator downward.
Vehicles with Air Conditioning (A/C):
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.
- Pivot the tensioner clockwise - arrow - to release the tension on the ribbed belt.
- Secure the tensioning element with the (T10060 A).
- Remove ribbed belt.
- Remove the bolts - arrows - and remove the generator from the accessory assembly bracket.
• If generator is stuck in its bracket, screw in mounting bolt again up to 2 rotations.
• Carefully strike on bolt heads using flat side of hammer - doing this loosens the bushings on the generator mount.
- Move the generator, the electrical wires still connected, to the right side of the vehicle.
- Disconnect the connector - 2 -.
- Remove the wire - 1 - and the clamp - 3 - from the generator.
- Remove the generator upward.
- Disconnect solenoid clutch electrical connector - 1 - on A/C compressor.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the bolts - arrows -.
- Remove the A/C compressor from the accessory assembly bracket and tie it up on the right side.
All Vehicles:
- Remove the coolant pipe by loosening the hose clamp - 1 -.
- Disconnect the connector - 2 - from the Mass Airflow (MAF) Sensor (G70).
- Detach upper section of the air filter housing - arrow - and remove air filter insert.
- Remove the bolts - arrows - and the lower section of the air filter housing.
- Remove the bolts - arrows - and the air filter housing bracket.
- Remove the connector - arrow - for the Heated Oxygen Sensor (HO2S) (G39) from the bracket, disconnect it and free it up.
- Remove the heated oxygen sensor - arrow - with a socket taken from the (3337).
- Remove bolt - arrow -.
- Remove the hose clamp - 1 - and lay the air guide pipe with the hose still connected - 2 - on the engine.
• Ignore - 3 -.
- Remove the bolts - arrows - and nuts - 1 - and then remove the heat shield.
- Remove the nuts - arrows - on the front exhaust pipe/turbocharger connection from the top.
- Remove the heat exchanger coolant hoses - arrows -.
- Remove the vacuum hose - 1 - from the non-return valve.
- Remove the non-return valve - arrow - from the brake booster.
- Pry cover caps off windshield wiper arms with screwdriver.
- Loosen nuts - arrows - a few turns.
- Position the puller for removing wiper arms (T10369/1) on the windshield wiper arm - 1 - as illustrated.
- Mount the pressure piece - 2 - on the wiper axle.
- Turn the bolt - 3 - clockwise until the wiper arm is pulled off the wiper axle.
- Remove the nuts completely and remove wiper arms.
- Remove gasket - 1 -.
The plenum chamber cover could be damaged.
• Coat the transition area between the windshield and plenum chamber cover - 2 - 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 plenum chamber cover - 2 - by carefully pulling cover out of retainer on windshield.
- Free up rear engine wiring harness on plenum chamber partition.
- Remove the Engine Control Module (ECM).
- Disconnect the engine wiring harness electrical connector - 1 - - arrow -.
- Release the engine wiring harness feed - 1 - through and remove upward - arrow -.
- Remove E-box cover by slide both latches in direction of - arrow -.
- Open wiring router bracket - arrows -.
- Unclip electrical connector - 1 - from bracket and disconnect.
- Open wiring router bracket below.
- Unclip engine wiring harness to engine control module from wiring router.
- Place engine wiring harness with engine control module on engine.
- Secure engine control module against falling down.
- Unclip electrical connector - 2 - from bracket and disconnect.
- Remove the terminal 30 wire - arrow - at the engine compartment E-box and free it up.
• To unclip spiral clip, use (80 - 200).
- Cut off cable ties - arrow - for protective boot - 1 -.
- Disconnect the connector - 2 -.
- Fold back protective boot and remove battery positive wire from starter solenoid.
- Remove ground (GND) wire - 3 -.
Risk of destroying control module (Mechatronic) with static discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge static electricity, touch vehicle ground with hand (without gloves).
- Disconnect electrical connector - 4 - by turning twist lock counterclockwise.
- Disconnect the connector - 1 -.
• Ignore - arrows -.
- Remove the subframe bolts - arrows - on the engine side 2 turns.
- Remove the subframe bolts - arrows - on the transmission side 2 turns.
- Mark position of flexible disc to bevel box flange for reinstallation.
- Remove the driveshaft flexible disc bolts - arrows - from the bevel box while counterholding at the triangular flange with a lever.
The shaft seal - arrow - in the driveshaft flange could be damaged.
• Press driveshaft horizontally as far back and to the right side of vehicle as possible.
- Remove the bolts - 1 - and - 2 - on the bracket for the oxygen sensor electrical connector under the vehicle floor. Remove the cover.
- Remove the bolt - 3 - and free up the electrical wire to the oxygen sensor.
- Remove the connector coupling - arrow - from the bracket.
- Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) (G130) and free it up.
- Remove the bolts - arrows -, exhaust system bracket and tunnel brace.
Risk of damaging decoupling elements.
• Do not bend decoupling element in front exhaust pipe by more than 10°.
- Loosen the nuts - arrows - at the clamping sleeve and separate the exhaust system.
- Remove the front exhaust pipe with the catalytic converter and front muffler.
- Remove bracket bolts - 1 -.
- Remove locking washer - 3 - - arrow - and remove selector lever cable from the transmission.
• Ignore - 2 -.
Risk of damaging sealing ring in driveshaft flange.
• Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.
- Remove bolts - 1, 2, 3 - and remove pendulum support.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Unclip bracket - 2 - for electrical wiring to oil level thermal sensor from subframe.
- Remove the right drive axle heat shield from bevel box - arrows -.
- Remove the left drive axle from the transmission flange and the right drive axle from the bevel box flange.
- Remove the air guide hose from the charge air cooler by loosening the hose clamp - arrow -.
- Free up the coolant hose - 2 -.
- Remove the bolts - 4 - and lay the after-run coolant pump (V51) with the coolant hoses still connected - arrows - to the side.
• Ignore - 1 and 3 -.
- Fasten the (T10012) to the cylinder block with bolt - 1 - and nut - 2 - to approximately 20 Nm.
- Place the (V.A.G 1383 A) on the (T10012) and raise engine/transmission assembly slightly.
• To remove subframe mounting bolts, use (VAS 5085).
- Remove the subframe bolts - arrows - on the engine side.
- Remove the subframe bolts - arrows - on the transmission side.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
• To prevent damage, carefully guide engine/transmission assembly when lowering.
- Pull the engine/transmission as far as possible to the front and left and slowly lower it while paying attention to the drive axles.