Engine, Removing
Special tools and workshop equipment required
- Lifting Tackle 3033
- Engine Support T40074
- 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
- Step Ladder VAS 5085
- Spring Type Clip Pliers VAS 5024 A
- Engine and Transmission Holder VAS 6095
- Shop Crane - Load Cap = 700-1200 KG VAS 6100
- Drip Tray for VAS 6100 VAS 6208 or Drip Tray V.A.G 1306
- Engine Support 3269
- Container for Removed Parts V.A.G 1698
- Engine Bung Set VAS 6122
- Cable Ties
Procedure
The engine with transmission is removed downward. The lock carrier service position is not necessary.
-- Check the Diagnostic Trouble Code (DTC) memories of all the control modules. Refer to the vehicle diagnostic tester.
All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
Leave the key in the ignition lock to prevent the steering lock from engaging.
It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can than be lowered on the hoist until the brake disc cover plates are just above the floor. This enables the most ergonomic work position regarding accessibility of components in the engine compartment.
When the engine is installed in the engine compartment, 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 the container for removed parts V.A.G 1698 for storage.
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.
Disconnect the battery ground strap with the ignition turned off. Refer to Removal and Installation .
-- Completely remove the air filter housing with the connecting pipe to the throttle valve control module -J338-. Refer to AIR FILTER HOUSING OVERVIEW .
-- Remove the air filter housing bracket. Refer to AIR FILTER HOUSING OVERVIEW .
-- Remove the windshield wiper arms and plenum chamber cover, refer to the following:
For the plenum chamber cover, refer to "Moldings and Trim" in Removal and Installation .
For the windshield wiper arms, refer to WINDSHIELD WIPER ARM .
Vehicles with a Engine Control Module (ECM) equipped with an Anti-Theft Immobilizer
-- Remove the locking bracket from the ECM. Refer to Engine Control Module -J623- WITH AN ANTI-THEFT IMMOBILIZER .
Continuation for all Vehicles
-- Disconnect the engine wiring harness connector from the ECM.
-- Release the pass-through for the engine wiring harness -arrow- and pull it off upward.
-- Remove the nut -arrow- and generator wire from the fuse holder.
-- Remove the bolt -arrow- and the ground wire from the longitudinal member.
-- Open the locking mechanisms -arrows- on the wire guide on longitudinal member.
-- Disconnect all harness connectors of the engine wiring harness/body and set down the engine wiring harness on the engine.
-- Disconnect the oxygen sensor wire connector on the plenum chamber bulkhead.
-- Disconnect all connectors from the transmission.
-- Remove all remaining electrical wires necessary from the engine/transmission and set aside.
-- Disconnect the shift lever cable from the transmission.
-- Remove the Evaporative Emission (EVAP) canister, the EVAP canister purge regulator valve 1 -N80- and hoses.
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. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully loosening the union nut.
-- Disconnect the ventilation line -1-, the vacuum line -2- and the fuel supply line -3-. To do this press the release button.
-- Disconnect the vacuum hose from the brake booster and intake manifold.
-- Seal the lines so that the fuel system is not contaminated by dirt, etc.
-- Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .
Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to eyes and scalding. Cover the cap with a rag and open very carefully.
-- Open and close the cap on the expansion tank, to relieve the cooling system pressure.
-- Remove the fan shroud and fans. Refer to FAN SHROUD AND FANS .
-- Remove the lower sections of the front wheel housing liners. Refer to Removal and Installation .
-- Disconnect the connector from the oil level thermal sensor -G266-.
-- Remove wire bracket from the oil level thermal sensor at the subframe.
To prevent damage to the Air Conditioning (A/C) condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
So that it is possible to remove the engine without opening the refrigerant circuit:
-- Remove the ribbed belt. Refer to RIBBED BELT .
-- Remove the A/C compressor from the accessory bracket with the refrigerant lines still connected. Refer to [For engine(s) BLV] Removal and Installation .
-- Secure the A/C compressor -A- to the lock carrier as shown (fasteners -1 and 2-).
-- Remove the right side drive axle protection.
-- Remove the drive axles. Refer to Removal and Installation .
Vehicles with All Wheel Drive (AWD)
-- Remove the driveshaft flexible disc bolts from the transmission. Refer to SPECIFICATIONS .
Continuation for all Vehicles
-- Remove the front exhaust pipe to exhaust manifold nuts -arrows-. Disconnect the oxygen sensor connector.
-- Remove the rear clamping sleeve and suspended mount from the front exhaust pipe. Remove the front exhaust pipe and oxygen sensors.
The oxygen sensors can remain installed.
Do not bend the coupling elements of the exhaust pipes more than 20° or they could be damaged. Two technicians are needed to perform the removal.
-- Remove the pendulum support bolts -1 through 3- and remove the pendulum support.
-- Drain the coolant. Refer to DRAINING AND FILLING .
-- Remove the coolant hoses from the radiator, the heater core and coolant expansion tank.
-- Remove the bolt -arrow- and disconnect the lines from the transmission. Catch any leaking fluid.
-- Install the engine support T40074 to the engine-/gearbox jack V.A.G 1383 A.
-- Remove the adapter T40074/1 from the engine support T40074 and install it to the cylinder block with a nut -1-.
-- Position the engine support T40074 to the engine as illustrated and install the adapter T40074/1 to the engine support T40074 -2-.
-- Secure the engine support T40074 to the exhaust side of the cylinder block with two M10 X 25 bolts -arrows- and tighten them to approximately 20 Nm.
-- Gently lift the engine and transmission using the engine-/gearbox jack V.A.G 1383 A.
-- Remove the engine mount to engine mount bracket bolt -arrows- from the top.
-- Remove the transmission mount to transmission mount bracket bolts -arrows- from the top.
Use the step ladder VAS 5085 to remove the bolts.
Carefully guide the engine with transmission, when lowering, to prevent damage to the body.
-- Carefully lower the engine with transmission.