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 Holder Bracket (T03000)
• Tensioning Strap (T10038)
• Cable Tie
• Foam Mat
Procedure
• To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, 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.
• Seal the disconnected fuel and ventilation lines to prevent dirt from getting into the system.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
• If the engine oil must be drained because of work performed on the removed engine, the oil should be drained with the engine installed. If the engine hangs on the engine lateral bracket (T03001) , the engine is not in its installed position and less engine oil flows out.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example , fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
- Check the Diagnostic Trouble Code (DTC) memories of all the control modules.
- Remove the engine cover with air filter. Refer to => [ Engine Cover with Air Filter ] Engine Cover with Air Filter.
- Remove the battery.
- Remove the E-box cover inside the engine compartment - arrows -.
Vehicles with a Automatic Transmission:
- Unclip the transmission control module - 3 - from the bracket - 7 - and remove it upward.
- Disconnect the connector - 2 - from the transmission control module.
Continuation for all Vehicles:
- Remove the bolts - 1 and 6 -.
- Move the bracket - 7 - with the power steering fluid reservoir to the side.
The hoses remain connected.
- Disconnect the connector - 2 - and free it up.
- Disconnect the connector - 4 - from the Engine Control Module (ECM) and free up the engine wiring harness.
- Remove the battery tray.
- Disconnect the harness connector - 4 -, open the locking mechanism and set the engine wiring harness - 3 - on the engine.
- Disconnect the Ground (GND) wire - 1 - and starter connections - 2 and 5 -.
Vehicles with a Automatic Transmission:
- Disconnect the connector - 6 - from the multifunction switch.
- Remove the selector lever cable from the transmission.
Vehicles with a Manual Transmission:
- Remove the shift mechanism from the transmission.
- Remove the brace - 1 -.
- Remove the slave cylinder bolts - arrows - and slave cylinder and set it aside, do not open the line.
Do not operate the clutch pedal after the slave cylinder has been removed. The slave cylinder may be damaged by doing this.
- Disconnect the connector from the backup lamp switch from the transmission.
Continuation for all Vehicles:
- Disconnect the vacuum hose from the brake booster.
- Disconnect the harness connector for the heated oxygen sensor (G39) on the bulkhead and free up the wiring harness.
- Open and close the cap on the coolant expansion tank, to relieve the cooling system pressure.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Remove the right front wheel housing liner.
To facilitate the removal and installation of the engine without having to open the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Service and Repair.
The refrigerant can cause serious personal injury.
• Do not open the Air Conditioning (A/C) refrigerant circuit.
Risk of damaging the refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the A/C compressor from the accessory bracket.
- Secure the A/C compressor to the bumper cover using a tensioning strap (T10038) and a suitable mat - A -. Slide the tensioning strap (T10038) as far as possible toward the bolt - arrow -.
- Remove the clamps for the power steering pressure line from the transmission.
- Remove the nuts - 1 - and the power steering pump hose.
• Ignore - 2 -
- Remove the power steering pump from the accessory bracket.
• The power steering lines remain connected to the power steering pump.
- Remove the 4 exhaust manifold to front exhaust pipe nuts - 2 - and the exhaust system suspended mount bolts - 3 -.
- Remove the front exhaust pipe - 1 - from the exhaust manifold and secure it firmly to the side. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe with Catalytic Converter.
• The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.
- Remove the right and left drive axles from the transmission.
- Remove the subframe without the steering gear.
The fuel system is under pressure!
• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect the fuel supply line - 2 -. Push the locking ring upward and into the housing.
- Disconnect the vent line - 1 -. Press the locking ring.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the bolt - 2 - and place the windshield washer reservoir - 1 - toward the front.
- Disconnect the connector - 3 -.
- Remove the bolts - 5 - and set down the coolant expansion tank - 4 - with the hoses connected onto the engine.
- Remove the coolant hoses from the heater core - arrows -.
- Open the spring clamps - arrows - and remove the coolant hoses from the radiator.
- Install the engine holder bracket (T03000) as follows:
• Remove the pin (T03000/1) from the engine holder bracket (T03000).
• Install the engine holder bracket (T03000) to the cylinder block with the pin - 3 - and tighten the bolts - 1 and 2 - hand tight.
• Then, install the pin (T03000/1) and tighten it 20 Nm.
• Then, tighten the bolts - 1 and 2 - to 25 Nm.
- Place the engine-/gearbox jack (V.A.G 1383 A) on the engine holder bracket (T03000) and lift the engine/transmission slightly.
Use a step ladder (VAS 5085) to remove the bolts from the engine/transmission mounts.
- Remove the engine mount from above. To do so, remove the bolts - 1, 2 and 3 -.
• The rear bolt - 2 - is accessible through a hole in the wheel housing.
- Remove the transmission mount bolts - arrows - from the transmission mount bracket.
• Verify that all hoses and lines between the engine/transmission and body have been disconnected.
• A 2nd technician is needed to lower the engine/transmission.
• The engine/transmission must be guided with care to prevent damage while lowering.
- Carefully lower the engine/transmission. When doing this, rotate or push the engine/transmission, as necessary.