Engine, Removing

Special tools and workshop equipment required

Shop Crane - Load Cap = 700-122 KG VAS 6100
Lifting Tackle 3033
Wrench SW 13T10384

NOTE:

Be sure to obtain the radio anti-theft code because it will be necessary to disconnect the battery ground cable later in the procedure.

The engine is removed forward 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.

WARNING:

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

Route all wires and lines so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

-- Disconnect the battery ground cable with the ignition turned off. Refer to Removal and Installation

-- Remove the air filter housing with the Mass Airflow (MAF) sensor and intake tube. Refer to AIR FILTER HOUSING OVERVIEW .

-- Remove the battery. Refer to Removal and Installation

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

Fig 1: Identifying Battery Holder Bolts

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-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the fuel filter and the auxiliary fuel pump -V393- or fuel pump 2 -V277-. Refer to Auxiliary Fuel Pump -V393- OR Fuel Pump 2 -V277- .

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

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Extract the refrigerant from the Air Conditioning (A/C) system. Refer to "A/C Service Station" in DESCRIPTION AND OPERATION .

-- Remove the lock carrier. Refer to Removal and Installation .

-- Remove the bolt -arrow- and move the windshield washer fluid reservoir filler tube to the side.

Fig 2: Removing Windshield Washer Fluid Reservoir Filler Tube

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-- Remove the coolant expansion tank and lay it on the engine.

-- Remove the bolt -arrow-, turn the intake tube -A- to the right and remove it.

Fig 3: Removing Intake Tube

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-- Remove the vacuum hoses -1 and 2- for the charge air regulation.

Fig 4: Removing Charge Air Regulation Vacuum Hoses

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-- Disconnect the connectors for the exhaust gas temperature sensor 1 -G235- -1-, the heated oxygen sensor -G39- -3- and for the exhaust gas temperature sensor 4 -G648- -2-.

Fig 5: Identifying Exhaust Gas Temperature Sensor 1/Oxygen Sensor/Connectors

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-- Disconnect the exhaust gas temperature sensor 3 -G495- connector -1- (attached behind the bracket).

Fig 6: Identifying Exhaust Gas Temperature Sensor 3

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-- Guide the wires out of the mounts on the plenum chamber bulkhead and on the turbocharger.

-- Remove the vacuum line from the vacuum pump.

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

Fig 7: Removing Refrigerant Line Bolt

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-- Remove the refrigerant line from the A/C compressor and move it to the side without bending it.

-- Open the quick-release couplings for the heater core hoses -arrows- on the plenum chamber bulkhead.

Fig 8: Heater Core Hoses Quick-Release Couplings

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-- Remove the nut and the starter positive wire -arrow- from the central electronics and place the wire on the engine.

Fig 9: Central Electronics Starter Positive Wire

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Vehicles with a Direct Shift Gearbox (DSG):

-- Remove the shift mechanism from the transmission. Refer to REMOVAL AND INSTALLATION .

-- Turn and unlock the Mechatronic unit connector -arrow- and disconnect it.

Fig 10: Mechatronic Unit Connector

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Vehicles with a Manual Transmission:

-- Remove the shift mechanism from the transmission. Refer to REMOVAL AND INSTALLATION .

-- Remove the hose/line assembly or plastic hose from the clutch slave cylinder. Refer to SLAVE CYLINDER WITH RELEASE BEARING .

Continuation for all Vehicles:

-- Remove the windshield wiper arms and the plenum chamber cover. Refer to the following:

Refer to Removal and Installation

Removal and Installation

-- Remove the plenum chamber bulkhead. Refer to Description and Operation .

-- Remove the Engine Control Module (ECM). Refer to Engine Control Module -J623-, WITH AN ANTI-THEFT IMMOBILIZER .

-- Release the engine wiring harness connector -arrow- and disconnect it from the ECM.

Fig 11: ECM Wiring Harness Connector

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-- Disconnect the connectors -1 and 2- on the left longitudinal member.

Fig 12: Left Longitudinal Member Connectors

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-- Disconnect the ground wire from the transmission.

-- Open the locking mechanism -A- inside the plenum chamber bulkhead.

-- Remove the upper part upward and remove the engine wiring harness from the wire guide.

Fig 13: Removing Engine Wiring Harness Wire Guide

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-- Disconnect all connectors between the starter, the transmission and the body.

-- Remove the bolt -arrow- at the top of the particulate filter bracket and loosen the bolt on the cylinder head just one turn.

Fig 14: Particulate Filter Bracket Bolt

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-- Disconnect the connector from the oil level thermal sensor -G266-.

-- Remove the drive axles. Refer to Removal and Installation .

-- Remove the bolts -1 through 3- and remove the pendulum support.

Fig 15: Identifying Pendulum Support & Bolts

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-- Loosen the clamp -1- between the particulate filter and the turbocharger.

Fig 16: Clamp Between Particulate Filter And Turbocharger

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-- Remove the nuts above the particulate filter mount using the wrench SW 13T10384.

-- Remove the nuts -arrows- for the particulate filter mount -A- on the crankcase and remove the mount.

Fig 17: Cylinder Head Bracket Bolt

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-- Move the particulate filter to the side and fasten it to the plenum chamber bulkhead.

NOTE:

Verify that all hose and wire connections between the engine, transmission and body have been disconnected.

-- Engage the lifting tackle 3033 as follows and support the engine/transmission subassembly with the shop crane - load cap = 700-122 KG VAS 6100.

Fig 18: Lifting Tackle 3033/ Shop Crane VAS 6100

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Vibration damper side:

Position 2.

Flywheel side:

Position 8.

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

Fig 19: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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

Fig 20: Identifying Removal Of Assembly Mounting On Transmission Side From Transmission Bracket

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NOTE:

When removing the engine/transmission subassembly, guide it out carefully to avoid damaging it.

-- Lower the engine/transmission subassembly slightly and remove it toward the front.

Secure the engine to the engine and transmission holder VAS 6095 whenever working on it ENGINE, SECURING TO Engine and Transmission Holder VAS 6095 .