Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor-Type Assembly Platform (VAS 6131 A) with Support Set (VAS 6131/10) and Supplementary Set (VAS 6131/11) and Supplementary Set (VAS 6131/13)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• During installation, cable ties must be installed at the same location.
Risk of vehicle tipping over with engine removed.
• Secure vehicle. Luggage compartment must be empty for this.
There is a risk of injury because the fuel is under very high pressure.
• Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.
- Reduce fuel pressure in high pressure area.
- Position the front wheels so they are straight.
• Release the electro-mechanical parking brake before disconnecting the battery so the driveshaft can be rotated to remove it.
Risk of destroying electrical components.
• Complete the steps for disconnecting the battery.
- Turn off the ignition and remove ignition key.
- Disconnect the Ground (GND) cable - 2 - from the battery post.
- Empty coolant circuit.
- Remove the lock carrier cover - 3 -.
- Remove the driveshaft.
- Remove the engine covers - 1 and 2 - upward.
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.
- Remove the cap - arrow - from the coolant reservoir.
- Remove the left and right front wheels.
- Remove the left and right wheel housing liners - 6 -.
- Remove the noise insulation - 1 and 2 -.
• Collect escaping coolant in a clean container for disposal or reuse.
- Place the (VAS 6208) under engine.
- Remove the drain plug - 1 - and drain the coolant.
- Lift the clip - 2 - and disconnect the coolant hose from the radiator.
- Loosen the clamp - 1 -, remove the coolant hose from the left lower coolant pipe and let the coolant drain out.
• Ignore - 2 -.
- Loosen the hose clamps - 1 and 2 -, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.
• The installed position is shown in the illustration with the engine removed.
• Ignore - 2 -.
- Remove the seal - 7 - from the plenum chamber bulkhead.
- Remove the plenum chamber cover - 3 -.
- Remove the bolts - arrows - and the air guide - 1 -.
• Ignore - 2 -.
- Free up the fuel hose - 1 - and the Evaporative Emission (EVAP) canister hose - 2 - on the air duct pipe.
- Remove the vacuum hose - 3 - from the air guide pipe connection.
- Remove the air guide pipe; to do this, loosen the hose clamps - arrows -.
- Remove the air filter housing - 1 - upward.
- Remove the secondary air hose - arrow - by pressing the release buttons.
- Loosen the clamp - 1 - and remove the vacuum connection from the plenum chamber bulkhead.
- Disconnect the electrical connector - 2 - on EVAP canister purge regulator valve 1 (N80) and disconnect the vacuum hose - 3 -.
- Disengage the EVAP canister purge regulator valve 1 from the bracket and lay it aside with the hoses connected.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
There is a risk of contamination.
• Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect the fuel line by first folding the boot - 1 - downward.
- First push the hose coupling - 2 - downward - arrow A -, then press the release buttons - arrows B -.
- Remove the hose coupling with the release buttons pressed.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Lift the clamp - arrow - and remove the coolant hose leading to the back of the heater core on the engine.
• The installed position is shown in the illustration with the engine removed.
- Open the clamp and remove the right front coolant hose - arrow - from the front coolant pipe.
- Open the clamp - 2 - and remove the coolant line.
- Remove the bolt - 1 - and free up the refrigerant line.
- Lift the clamp - arrow -, free up the coolant hose and remove the left coolant hose from the coolant pipe.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the bolt - 2 - and then remove the refrigerant line from the Air Conditioning (A/C) compressor.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Ignore - 1 and 3 -.
- Remove the strut tower brace.
- Release the retainer - arrow A - and open the cover - arrow B -.
- Remove the nuts - 2 and 3 - and free up the wire.
- Remove the electrical connector - 1 - from the bracket and disconnect it.
- Remove the nuts - arrows - and then remove terminal 30 wire junction (TV2) from the plenum chamber bulkhead.
- Move the foam wedge - 1 - to the side.
- Remove the bolts - arrows -.
- Open the retainers - arrows - and free up the wiring guide - 2 -.
- Remove the cap nut - 1 - and free up the ground (GND) cables.
- Remove the bolts - arrows -, pull the filler tube - 1 - out of the windshield washer fluid reservoir and out of the opening in the body and move it to the right.
- Remove the cap nut - 2 - and free up the Ground (GND) cable.
- Open the retainers - arrow - and remove the Engine Control Module (ECM) (J623) - 1 -.
- Remove the bolts - arrows - and the cover - 1 - from the plenum chamber E-box.
- Disconnect the electrical connectors - 1 - and remove the nut - 2 - for the electrical wire.
- Release the retainers - arrows - and remove the relay carrier with the fuse panel - 3 -.
- Disengage the engine wiring harness from the plenum chamber E-box and free it up.
- Release the retainers - A arrows - and remove the wiring bushing - 1 - upward - arrow B -.
- Lay the wiring harness on the engine and secure the ECM so that it cannot fall.
- Disconnect and free up the connector - 2 - on the charge air cooling pump (V188).
• Ignore item - 1 - and - arrows -.
- Disconnect the radiator fan electrical connectors - 1 - and - 2 -, to do this, push the clamp to the rear - arrow - and push the release down.
- Free up the wiring harness.
- Disconnect the connector - 4 - on the Secondary Air Injection (AIR) pump motor (V101).
- Press the release buttons and remove the secondary air hose - 2 -.
• Ignore items - 1 and 3 -.
- Remove the left and right bolts - arrows - and the lower front longitudinal member - 1 -.
- Disconnect the connector - arrow - from the right front ABS wheel speed sensor (G45) / left front ABS wheel speed sensor (G47).
- Disconnect the left and right connector - 1 - from the left front level control system sensor (G78) / right front level control sensor (G289) and free up the wire - arrow -.
- Free up the electrical connector - 2 - on the bracket by pulling the retainer back - arrow A - and turning the connector approximately 90° clockwise - arrow B -.
- Free up the electrical wiring - 3 - and brake line - 4 - on the bracket.
- Remove the bolts - 1 - and secure the brake caliper, with the brake line still connected, inside the wheel housing using wire.
Risk of damaging brake pistons.
• Do not operate brake pedal when the brake caliper is removed.
- Remove the nut - 2 - and the bolt - 1 -.
- Remove the upper control arm upward from the wheel bearing housing - arrows -.
- Repeat the procedure on the other side of the vehicle.
- Remove the left and right stabilizer bar bolt - 1 -.
- Remove the left and right nuts - 3 -.
• The bolts - 2 - will be removed later.
- Remove the subframe crossbrace.
Suspension components could be damaged.
• Do not rest the vehicle on its wheels if the subframe mount, steering gear or subframe crossbrace are not installed correctly.
- Remove the left and right bolts - arrows - and the heat shield - 1 -.
- Remove the nuts - arrows - and the left front muffler.
- Remove the nuts - arrows - and the right front muffler.
- Remove the steering intermediate shaft from the steering gear and push it upward.
- Open the retainer - arrow - and push it down and then disconnect the connector - 2 - from the steering gear.
- Disconnect the connector - 1 -.
- Free up the wiring harness.
Prepare Scissor Lift Platform
- Equip the scissor-type assembly platform (VAS 6131 A) with support set (VAS 6131/10) and supplementary set (VAS 6131/11) and supplementary set (VAS 6131/13) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position the (VAS 6131 A) horizontally.
• Note bubble level (sight glass) on support platform.
- Move the (VAS 6131 A) under the engine/transmission subassembly.
The subframe could cause an accident if it is not secured.
• Do not loosen the subframe bolts - 2 and 3 -.
- Remove the left and right subframe bolts - 1 -.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the left and right front of the subframe as shown in the illustration.
- Ensure threaded spindles are completely installed.
- Attach the mounting elements from the (VAS 6131/10) at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.
- Attach mounting elements from the (VAS 6131/13) at the lower left and right of the wheel bearing housing as shown in the illustration.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/11) at the left and right rear of the tunnel crossmember as shown in the illustration.
- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.
- Attach mounting element base plates to the (VAS 6131 A) and tighten to 20 Nm.
- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.
- Remove the left and right subframe bolts - 2 - and - 3 - in a diagonal sequence in stages.
- Remove the bolts - arrows - on the tunnel crossmember.
- Remove the left and right bolts - 2 -.
Risk of damaging hose and wiring connections as well as the 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 the engine compartment while lowering.
- Next lower engine/transmission subassembly with the (VAS 6131 A) only by dimension - a -.
• Dimension - a - = 100 mm maximum.
- Remove the selector lever cable ball socket - 2 - from the transmission shift lever using the (80 - 200).
- Press the securing clips - 1 - off and remove the selector lever cable from the transmission.
• Do not bend or kink selector lever cable.
- Lower the engine/transmission subassembly more.
- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.