Engine, Removing
Engine, removing
Note: During this procedure the battery Ground strap must be disconnected. Check whether a coded radio is installed. Obtain the radio code first, if necessary.
The engine is removed in a downward direction together with the transmission.
CAUTION! When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: All cable ties which are opened or cut open when removing the engine must be replaced in the same position when installing the engine.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Remove left and right sound insulation.
- Drain coolant.
- Remove battery and battery retainer.
- Observe rules for cleanliness.
WARNING!
^ Fire Hazard! Do NOT have anything in the area that can ignite fuel!
^ The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.
Engine codes AEG, AVH, AZG
- Disconnect these hose connections and collect fuel that leaks out with a cloth.
1 - Vacuum hose to Throttle valve control module -J338-
2 - Fuel return hose (with blue markings)
3 - Fuel supply hose (with white markings)
Engine codes BBW, BEV
- Disconnect fuel supply line -1- off union by pressing locking ring -2- into union -3-.
Continued for all vehicles
- Seal lines to avoid contamination of fuel system.
Note: Seal the intake ports in the intake manifold lower section with clean cloths.
- In preparation for further disassembly work disconnect connectors from following components:
Camshaft Position (CMP) sensor -G40-
Fuel Injectors -N30- to -N33-, unclip cable guide
Engine Coolant Temperature (ECT) sensor -G62-
Engine speed (RPM) sensor -G28-
Knock Sensor (KS) 1 -G61-
Knock Sensor (KS) 2 -G66-
Oil pressure switch -F1-
Mass Air Flow (MAF) sensor -G70-
Throttle valve control module -J338-
A/C cut-out thermal switch -F163-
Engine code BBW
Valve -1- for camshaft adjustment -N205-
Ignition coils with power output stages -N70-, -N127-, -N291-, -N292-
Secondary Air Injection (AIR) pump motor -V101-
Engine code AEG, AVH, AZG
Ignition coils (-N- and -N128-) with power output stage -N122-
Secondary Air Injection (AIR) pump motor -V101-
Engine code BEV
Ignition coils with power output stages -N70-, -N127-, -N291-, -N292-
Secondary Air Injection (AIR) pump motor -V101-
Continued for all vehicles
- Remove air cleaner.
- Remove interconnecting, coolant, vacuum and intake hoses on engine.
- Remove intake manifold upper part.
Note: Seal the intake ports in the intake manifold lower part with a clean cloth.
Vehicles with manual transmission
- Disconnect shift mechanism from transmission.
- Remove hydraulic clutch slave cylinder.
Note: The clutch pedal must not be operated.
Vehicles with automatic transmission
- Disconnect selector lever cable from transmission.
Continued for all vehicles
- Remove poly V-belt.
- Remove securing clamps for power steering pressure line.
- Remove power steering pump from bracket and lay to side; hoses remain connected.
Vehicles with air conditioning
- Remove air conditioning compressor.
Continued for all vehicles
- Disconnect hoses from engine.
- Vehicles with secondary air pump: remove secondary air pump motor and bracket.
- Disconnect all electrical wiring from transmission, Generator and starter and move clear.
- Disconnect all other electrical connections from engine and lay to one side as necessary.
- Unbolt pendulum support (arrows).
- Remove protective cover for right side inner constant velocity joint from engine.
- Remove right axle shaft and disconnect left axle shaft at transmission.
- Remove front exhaust pipe.
- Disconnect connector for oxygen sensor before catalytic converter and move wiring clear.
- Depending on version, remove oil pan protection, and remove rubber bushings.
- Insert engine bracket T10012 in engine/transmission jack V.A.G 1383 A.
- Secure engine bracket T10012 to front of cylinder block with securing bolt M10 x 25 (8.8) to 40 Nm.
- Tighten securing nut on exhaust side hand tight.
- Lift engine and transmission lightly using engine/transmission jack V.A.G 1383 A.
- Unbolt engine side of assembly mounting from top of engine carrier (arrows).
Note: Use step ladder VAS 5085 or equivalent to remove securing bolts.
- Unbolt transmission side of assembly mounting from top of transmission carrier (arrows).
- Carefully lower engine with transmission.
Note: Engine and transmission must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines/wiring.