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)
• Guide Pins (T10093)
• Adapter (T10467)
• Cable Ties
• Foam Mat
Before beginning work, refer to the following safety precautions:
• => [ Working on Fuel System ] Working on Fuel System
• => [ Coolant System ] Coolant System
• => [ Working on Ignition System ] Working on Ignition System
• => [ Clean Working Conditions ] Clean Working Conditions
• 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, it should be performed 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 will drain 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 control modules. Refer to the vehicle diagnostic tester.
- Remove the air filter (engine cover). Refer to => [ Air Filter and Engine Cover ] Air Filter and Engine Cover.
- Remove the intake hose - 4 - between the throttle valve control module (J338) and air filter. To do so, disconnect the hose - 1 -, if present, and the hose - 2 - (compress the securing ring) and remove the spring clamp - 3 -.
- Remove the intake air scoop bolts - arrows - and scoop from the lock carrier.
- 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.
- Remove the nut and free up the wire - 5 -.
- Disconnect the connector - 4 - from the Engine Control Module (ECM) and free up the engine wiring harness. Refer to => [ Motronic Engine Control Module (J220) ] Service and Repair.
- Remove the battery, the battery bolts - arrows - and tray.
- Disconnect the connector - 4 -, open the locking mechanism and lay the engine wiring harness - 3 - on the engine.
- Remove the nut and the ground wire - 1 -. Disconnect the 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 bolts and the brace - 1 -.
- Remove the slave cylinder bolts - arrows - and slave cylinder and set it aside, do not open hydraulic system.
Do not operate the clutch pedal anymore after the slave cylinder has been removed. The slave cylinder may be damaged by doing this.
- Disconnect the connector from the backup lamp switch on the transmission.
Continuation for all Vehicles:
- Disconnect the vacuum hose from brake booster.
- Disconnect the connector from the heated oxygen sensor (G39) on the bulkhead. Move the wiring harness to the side.
- Open the cap on the coolant expansion tank and then close it again to release the pressure in the coolant system.
- Drain the coolant. Refer to => [ Draining and Filling ] Service and Repair.
• The vehicle has a manual hood support that is attached to the lock carrier.
- Bring the lock carrier into the service position. Procedures
- Remove the fan shroud. Refer to => [ Fan Shroud and Fans ] Fan Shroud and Fans.
To facilitate removal and installation of the engine without having to open the refrigerant circuit:
- Remove the ribbed belt. Refer to => [ Ribbed Belts ] Ribbed Belts.
Refrigerant can cause serious personal injury.
• Do not open the Air Conditioning (A/C) refrigerant circuit.
- Remove the A/C compressor from the accessory bracket.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Secure the A/C compressor to the bumper cover using a tensioning strap (T10038) and a suitable foam mat - A -. Slide the tensioning strap (T10038) as far as possible next to the bolt - arrow -.
- Remove the clamps - arrows - for the power steering pressure line from the transmission.
- Remove the nuts - 1 - and the power steering pump hose.
- If the vehicle has an engine pre- warmer, disconnect the cable - 2 -.
- Remove the power steering pump from the accessory bracket and set it down at the front.
• The power steering lines remain connected to the power steering pump.
- Remove the four front exhaust pipe nuts - 2 - and the exhaust system suspended mount bolts - 3 -.
- Remove the front exhaust pipe - 1 - from the exhaust manifold and tie it to the side. Refer to => [ Exhaust Pipe with Catalytic Converter ] Service and Repair.
Danger of causing damage to the flex coupling element:
• Do not bend the flex coupling element more than 10°.
• Do not stretch the flex coupling element.
• Do not damage the wire mesh on the flex coupling element.
- Remove the right drive axle.
- Remove the left drive axle from the transmission.
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 disconnecting the line.
- Disconnect the fuel supply line - 1 - and the ventilation line - 2 -.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Disconnect the coolant hoses - arrows - from the heater core.
- Open the spring clamps - arrows - and remove the coolant hoses from the radiator.
- Remove the bolt - 2 - and move the windshield washer filler tube forward - 1 -.
- Disconnect the connector - 3 -.
- Remove the bolts - 5 - and place the coolant expansion tank - 4 - on top of the engine with the hoses connected.
• Loosen the bolts for the engine and transmission mounts one turn.
- 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 (T03000/1) - 3 - and tighten bolts - 1 and 2 - hand tight.
• Then, screw in the pin (T03000/1) and tighten it to 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 raise the engine/transmission subassembly slightly.
Use a step ladder (VAS 5085) to remove the bolts from the engine/transmission mount.
- Remove the engine mount from above. To do so, remove the bolts - 1, 2 and 3 -.
• The rear bolts - 2 - are accessible through a hole in the wheel housing.
- Remove the transmission mount bolts - arrows -from the transmission mount bracket.
• Verify that all hoses and wires between the engine/transmission subassembly and body have been disconnected.
• A 2nd technician is needed to lower the engine/transmission subassembly.
• The engine/transmission subassembly must be guided with care to prevent damage while lowering.
- Carefully lower the engine/transmission subassembly. When doing this, rotate or push the engine/transmission subassembly.