Engine, Removing

Engine, Removing

Special tools, testers and auxiliary items required

• 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)

• Spring Type Clip Pliers (VAS 5024 A)

• Step Ladder (VAS 5085)

• Engine/Trans. Support (T10012)

• Cable Ties

• To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand.

• 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.


When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Procedure

- Disconnect the battery ground cable with the ignition turned off.

- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover With Air Filter.

- Remove the battery, the battery tray bolts - arrows - and tray.






- Remove the plenum chamber cover.

- Remove the plenum chamber bulkhead.

- Disconnect the harness connector from the Engine Control Module (ECM).

- Release the pass through for the engine harness - arrow - and pull it off upward.






- Remove the E-box cover by sliding both latches in the - direction of the arrows -.






- Remove the nuts, the generator cable - A - and the battery cable - B - from the fuse holder.






- Remove the bolt and the ground wire - arrow - from the longitudinal member.






- Open the locking mechanisms - arrows - on the wire guide on the longitudinal member.






- Free up the electrical connector - 1 - and disconnect it.






- Open the underlying wiring guide bracket - 2 -.

- Take the ECM wiring harness out of the wiring router and lay it on the engine.


The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Lay a cloth at the connection points before loosening the hose connections. Then reduce the pressure by carefully removing the hose.

- Disconnect the vent line - 1 - and the fuel supply line - 2 -.






- Disconnect the vent line - 2 - and remove the Evaporative Emission (EVAP) canister with the hoses, upward out of the mount.






- Remove the noise insulation.

- Remove the left and right front wheel housing liners.

- Remove the charge air hoses - arrows -.






- Remove the right drive axle heat shield bolts - arrows - and shield.






- Remove the driveshaft.

- Remove the right and left drive axles.

- Remove the exhaust pipe with catalytic converter. Refer to => [ Exhaust Pipe with Catalytic Converters ] Service and Repair.

- Move the lock carrier into the service position. Procedures

- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.

- Evacuate the Air Conditioning (A/C) system.

- Remove the refrigerant line bolt - arrow - and line from the A/C compressor.






- Remove the refrigerant line bolt - arrow - and line from the A/C condenser.






- Remove the pendulum support bolts - 1, 2 and 3 - and remove the pendulum support.






- Disconnect all remaining electrical connectors necessary from the engine and transmission and set aside.

- Disconnect all coolant, vacuum and intake connections from the engine.

- Remove the shift mechanism from the transmission.

- Clamp off the hose - A -to the clutch slave cylinder using a hose clamp up to 25 mm dia. (3094).






- Pull the hose/line assembly clip - arrow - out as far as the stop.

- Disconnect the hose/line assembly from the slave cylinder.


The clutch pedal must no longer be pressed down.

- Remove the coolant recirculation pump (V50) bolts - arrows -.






- Install the engine/trans. support (T10012) onto the engine-/gearbox jack (V.A.G 1383 A).

- Install the engine/trans. support (T10012) to the engine as shown and tighten the bolt - 1 - and nut - 2 - to 20 Nm.






- Support the engine and transmission using the engine-/gearbox jack (V.A.G 1383 A).

- Remove the engine mount to engine mount bracket bolts - arrows -.






- Remove the transmission mount to transmission mount bracket bolts - arrows -.






• Use the step ladder (VAS 5085) to remove the bolts.

• Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.

- Carefully lower the engine and transmission.