Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Lifting Tackle VAS 3033
Drip Tray VAG 1306
Engine and Transmission Holder VAS 6095
Shop Crane - Load Cap = 700-1200 KG VAS 6100
Scissor Lift Table VAS 6131
Engine-/Gearbox Jack VAG 1383A
Support F/ VAS 6131 for V6/V10/V8 VAS 6131/8
Step Ladder VAS 5085
Torque Wrench (5-50 Nm) VAG 1331

The engine and transmission are removed downward.

-- Check the Diagnostic Trouble Code (DTC) memories of all control modules, before removing the engine. Refer to the vehicle diagnostic tester.

NOTE:

To allow free rotation of the driveshaft, move the selector lever to the "N" position.

Leave the key in the ignition lock to prevent the steering wheel lock from engaging.

It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the brake disc cover plates are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment.

When the engine is installed some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing the engine.

To prevent damage to the removed components, use a container for removed parts VAG 1698 as storage.

All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.

Battery, Disconnecting

The procedure must be strictly followed!

-- Turn off the ignition and all electrical components.

-- First, disconnect the battery under the driver's seat. Refer to Removal and Installation .

Procedure

-- Remove the left and right wiper arms. Refer to WIPER ARMS .

-- Pull the engine compartment cover seal off the bulkhead.

-- Remove the covers -A, B and C- in the engine compartment.

Fig 1: Identifying Covers

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WARNING:

Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully loosening the connection.

-- Place a cloth around the connection to catch any leaking fuel.

-- Disconnect the fuel supply line -arrow-.

Fig 2: Identifying Fuel Supply Line

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-- Disconnect the breather line -arrow- to the solenoid valve in the engine compartment.

Fig 3: Identifying Breather Line To Solenoid Valve

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-- Disconnect the small electrical connector -A- from the Engine Control Module (ECM) -1- and disconnect the ground connection -arrow- of the wiring harness.

Fig 4: Identifying Small Connector, Engine Control Module (ECM) J623, And Wiring Harness Ground Connection

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-- Open the fuse box cover on the left side in the plenum chamber and separate connectors -A, B and C-.

Fig 5: Identifying Connectors In Fuse Box

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-- Remove the wiring harness from the plenum chamber and set it on the engine.

-- Remove the starter wire nut -1-, and wire and lay it aside on the engine.

Fig 6: Connecting Alligator Of Remote Control To B+ Connection

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-- Disconnect the connector from the left Mass Airflow (MAF) sensor, and remove the intake hose and left air filter housing.

-- Disconnect the connectors -1 through 4- for the oxygen sensors and place the connectors on the engine.

Fig 7: Identifying Connectors For Oxygen Sensors

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NOTE:

Connector for cylinder bank 1 = Black, connector for cylinder bank 2 = Brown.

-- Remove the right intake hose to from the throttle valve control module.

-- Pull the intake hose to secondary air injection pump motor -V101- off from the upper part of the air filter and remove the upper part of the air filter.

-- Remove the air filter element.

-- Disconnect the air suspension compressor connecting line -arrow- from the right air filter housing. Refer to CONNECTING LINE TO AIR SUSPENSION COMPRESSOR, DISCONNECTING .

Fig 8: Identifying Connecting Wire To Air Suspension Compressor

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-- Unclip the transmission breather line from the air filter housing.

-- Remove the bracket for the right engine cover. Refer to Fig 9.

Fig 9: Removing Bracket For Right Engine Cover

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-- Pull the lower part of the air filter off to the right from the air duct -item 10 - in the AIR FILTER HOUSING OVERVIEW , and remove it.

-- Recover the refrigerant from the Air Conditioning (A/C) system. Refer to Description and Operation .

-- Disconnect the A/C lines from the A/C compressor.

-- Remove the noise insulation tray. Refer to Description and Operation .

-- Loosen the double clamp between the catalytic converter/center muffler and push the clamp forward.

-- Support the exhaust system between the rear muffler and center muffler using the engine-/gearbox jack VAG 1383A, remove the mountings and lower the exhaust system.

-- Remove the driveshaft. Refer to [For transmission(s) 09D] Removal and Installation .

-- Remove the front wheels.

-- Remove the front wheel housing liners. Refer to Description and Operation .

-- Separate the hose connection from the vacuum reservoir, in the left front wheel housing.

-- Remove the heat shield -A- from the steering column and loosen the universal joint bolt -B-. Refer to Description and Operation .

Fig 10: Identifying Universal Joint Bolt

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-- Disconnect the connectors -A- from the transmission and connectors -B- from the transfer case and loosen the selector lever cable. Refer to [For transmission(s) 09D] Removal and Installation .

Fig 11: Identifying Connectors At Transmission And Transfer Case

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-- Disconnect the brake lines in the wheel housing at the brake hose and catch any brake fluid which runs out. Refer to Removal and Installation .

-- In the wheel housings, separate all connectors between the body and front axle.

-- Disconnect the air suspension connecting lines from the strut.

-- Remove the transmission transverse support -A-.

Fig 12: Identifying Transmission Transverse Support

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WARNING:

Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and from scalding. Cover the cap with a cloth and open very carefully.

-- Open and close the cap on the expansion tank, to relieve the cooling system pressure.

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- From the left wheel housing, separate the hose connections to the heater core and catch any leaking coolant.

-- Remove the upper coolant hose from the radiator, and the lower coolant hose from the coolant pipe.

-- Disconnect the left front coolant lines through the left front wheel housing, if necessary

-- Disconnect the lines -arrow- from the transmission oil cooler at the lower right. Catch any fluid which runs out.

Fig 13: Identifying Line From Transmission Oil Cooler

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-- Disconnect the line from the power steering fluid cooler below on the left. Catch any fluid which runs out.

-- Remove the ground wire bolt -1- from the longitudinal member at the right front.

Fig 14: Identifying Ground (GND) Wire, Coolant Hose, And Bracket

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-- Remove the coolant hose clamp -3- and hose and unfasten the coolant pump with the bracket -2-.

-- Remove one of the rear mounting bolts -3-.

-- Secure the subframe to the body. Refer to Description and Operation .

Fig 15: Identifying Subframe Bolts And Transmission Transverse Support

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-- Then proceed in exactly the same way with the other mounting bolt -3-.

-- From the area of the plenum chamber, remove the two least accessible bolts from strut on each side of vehicle. Refer to Removal and Installation .

Preparing the Scissor Lift Table VAS 6131

-- Mount the front support VAS 6131/6-1 on left -1- and the front support VAS 6131/6-2 on the right -2- of the lift table. The arrows on the supports point in the direction of travel. Fasten the bolts at the following positions: Left support -1- : A5, B4 and B5. Right support -2- : G4, H4 and H5

Fig 16: Preparing Scissor Lift Table VAS 6131

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-- Bolt the axle supports VAS 6131/6-3 and 6131/6-4 -3- to the lift table at the following positions: Left axle support: A6 and C6. Right axle support: F6 and H6

-- Rotate the turntables for the axle supports downward.

-- Place the supports VAS 6131/6-5 -4- for the subframe and the supports VAS 6131/6-6 -5- for the transmission bracket in the corresponding positions on the lift table.

-- Move the horizontally aligned lift table under the powertrain assembly. The supports -1- must be guided into the corresponding mount -arrow- at right and left.

Fig 17: Identifying Supports And Mounts

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-- Simultaneously, guide the right and left supports for the transmission bracket into the corresponding holes -arrow-. When all four supports are in the appropriate holes without pressure:

Fig 18: Right And Left Supports For Transmission Console Guided Into Corresponding Holes

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-- Extend both turntables for the axle supports with slight preloading under the control arms.

-- Guide the support -2- into the corresponding mount in the subframe, if necessary check the support height on the knurled nut.

Fig 19: Identifying Supports And Mounts

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-- Loosen the subframe bolts -1 and 2- and the transmission transverse support -4-.

Fig 20: Identifying Subframe Bolts And Transmission Transverse Support

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-- Use the step ladder VAS 5085 and remove the respective third bolt of the strut.

-- Slowly lower the engine/transmission assembly, constantly observing for clearance.

Removal Procedure Continued

-- Support the transmission using the support VAS 6131/6-7 on the lift table.

-- Remove one of the lower engine to transmission bolts.

-- From the engine side, insert the angled guide pin from the support f/ VAS 6131 for V6/V10/V8 VAS 6131/8 into the threaded hole.

-- Fasten the supports, positioned free of stress, to the table.

-- Remove all engine and transmission bolts.

NOTE:

To separate the engine and transmission, refer to the operating instructions for the scissor lift table VAS 6131.