Engine, Removing

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

Special Tools And Workshop Equipment Required

Engine and Gearbox Jack :VAS6931
Engine Bung Set :VAS6122
Shop Crane - Drip Tray :VAS6208
Hose Clip Pliers :VAS6362
Locking Pin :T10060A
Engine Support :T10497 with Pins :T10497/1
Engine Support - Clamp :T10497/4
Securing element from the Transmission Support :3282
Pry Lever :80-200
Protective Mat :VAS531003
Commercially Available Step Ladder
Protective Eyewear
Safety Gloves

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Bolts - Engine mount
Bolts - Transmission mount

Procedure

CAUTION:

The cooling system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

Wear safety gloves.
Wear protective eyewear.
Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the coolant expansion tank cap -arrow-.

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-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery tray. Refer to BATTERY .

-- Remove the radiator. Refer to RADIATOR, REMOVING AND INSTALLING .

-- To prevent damage, cover the charge air cooler using suitable service equipment.

-- Loosen the hose clamps -1 and 3-.

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-- Disconnect the connector from the Charge Air Pressure Sensor -G31- -arrow-.

-- Remove the bolts -2 and 4- and remove the air duct pipe -5- downward.

-- Remove the vacuum hose -3- from the connection -arrow-.

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-- Press the vacuum hose release buttons -2- and remove from the vacuum pump -1-.

-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

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NOTE:

There may be a heat shield installed that does not need to be removed.

-- Hold the coolant hoses downward and allow the coolant to drain.

-- Remove the left and right front wheel housing liner. Refer to WHEEL HOUSING LINER .

Vehicles With Secondary Air System

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-- Press the release -arrows- and remove the lines -1- from the Secondary Air Injection Pump Motor -V101- -2-.

Continuation For All Vehicles

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-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Unclip the hoses from the bracket -arrow- of the expansion tank -3-.

-- Disconnect the hose couplings -1 and 2-.

-- Loosen the nuts -arrows- to disconnect the battery positive cables -1- from the E-box -2-.

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Vehicles With Secondary Air System

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-- Squeeze the locking ring on both sides to remove the connecting pipe -1-.

-- Carefully unclip the secondary air line bracket -4-.

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-- Unclip the clip -3- and remove both secondary air lines.

Continuation For All Vehicles

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-- Remove the ground connection -2- and free up the cable guide -1-.

-- Release and disconnect the connectors -3-.

-- Open the locking mechanisms -arrows- for the cable guide -1- and place the wiring harness on the engine.

-- Disconnect and remove the connectors -arrow-.

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-- Unclip the wiring harness from the bracket -1-.

NOTE:

Do not bend or kink the selector lever cable.

-- Remove the selector lever cable from the transmission.

-- Remove the bolts -arrows- and set the selector lever cable -2- with the cable bracket -1- aside.

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EVAP Canister In Engine Compartment

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-- Remove the breather line -arrow-. .

-- Release the tab -3- in the direction of the -arrow- and remove the EVAP canister -1- upward.

-- Lay the EVAP canister -1- on the engine with the line attached -2-.

Continuation For All Vehicles

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-- Remove the bolt -4- and rotate the washer fluid reservoir filler tube -2- forward.

-- Open the clip -3- and remove the connector -5- from the coolant expansion tank -1-.

-- Remove the bolts -arrows- and place the coolant expansion tank -1- on the engine with the hoses connected.

-- Loosen the bolts -1- for the engine mount -2- approximately two turns.

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-- Loosen the bolts -2- on the transmission mount -1- two turns.

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-- Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation.

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-- Move the tensioner in the direction of -arrow- to release the tension on the ribbed belt.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioner. If necessary, remove the :T10060A .

CAUTION:

Danger of frostbite from refrigerant.

Do not open the A/C system refrigerant circuit.

-- Disconnect the connector -1- from the A/C Compressor Regulator Valve -N280-.

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-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached.

-- Remove the left and right drive axle. Refer to DRIVE AXLE . .

Vehicles With Coolant Auxiliary Cooler

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-- Remove the nuts -arrows- from the coolant auxiliary cooler bracket -2-.

-- Unclip the air duct on the coolant auxiliary cooler.

-- Remove the coolant auxiliary cooler -1- with the bracket -2- and attached coolant hoses and secure to engine.

Continuation For All Vehicles

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-- Remove the connector -arrow- from the After-Run Coolant Pump -V51- -1-.

-- Remove the nut -3- and remove the After-Run Coolant Pump -V51- -1- from the bracket -2-.

-- Press the release -arrow- and remove the coolant hose -1- from the controller housing.

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-- Remove the bolts -arrows- and move the bracket to the side.

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-- Remove the bolt -arrow- for the bracket -1-.

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-- Lightly push the wire -2- upward.

-- Position the :T10359/3 on the :T10359A from above and secure it.

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-- Tighten the :T10359/2 onto the engine bracket with the securing element -A- from the :3282 .

-- Position the :T10359A on the :VAS6931 and bring it into position with the engine/transmission assembly.

-- After the :T10359A is positioned correctly, install the bolt -A- with the spacer sleeve on the :T10359A .

-- Secure the engine bracket on the engine using the securing element -B- from the :3282 and slightly lift the engine/transmission assembly.

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-- Completely remove the bolts -1- for the engine mount -2-.

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NOTE:

Depending on the transmission there can be two or three bolts installed.

-- Remove the bolts -2- completely.

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-- Carefully lower the engine/transmission assembly in the direction of -arrow 1-.

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-- Carefully guide the engine/transmission assembly forward and out to the left in the direction of -arrow 2-.