Engine, Removing: Procedure

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-- When installing, bring all cable ties back to same positions.

NOTE:

The engine is removed downward together with the transmission.

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.

-- Open the coolant reservoir cap -arrow-.

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-- Remove the left and right front wheels. Refer to WHEEL, CHANGING or WHEELS AND TIRES .

-- Remove the noise insulation. Refer to NOISE INSULATION .

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

-- Place the :VAS6208 underneath.

-- Disconnect the connector -1- from the Engine Coolant Temperature Sensor on Radiator Outlet -G83- -2-.

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-- Lift the clamp -3- and remove the lower right coolant hose from the radiator.

-- Allow the coolant to drain.

-- Lift the clamp -arrow- and remove the lower right coolant hose from the charge air cooling circuit radiator.

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-- Allow remaining coolant to drain.

-- If the ribbed belt must be reinstalled, then mark the running direction with chalk or a felt-tip pen for reinstallation.

Vehicles With A/C Compressor

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-- To release the tension on the ribbed belt, turn the tensioner counter-clockwise in the direction of -arrow-.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley.

-- Secure the tensioner using the :T10060A .

-- Remove the ribbed belt.

CAUTION:

- 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 A/C compressor bolts -arrows-.

NOTE:

Do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the A/C compressor with the refrigerant lines connected and tie it up on the right side.

Continuation For All Vehicles

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-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

-- Lift the clamp -arrow- and remove the upper right coolant hose from the charge air cooling circuit radiator.

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-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Attach the :VAS531003 to the vehicle as shown.

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-- Disconnect the battery. Refer to BATTERY .

-- Remove the battery and the battery tray. Refer to BATTERY .

-- Open the retainer -arrow- and remove the vacuum hose -1-.

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-- Free up the vacuum hose on the air duct pipe -2-.

-- Lift up the clips in the direction of -arrow-. Remove the coolant hoses -1 and 2- from the heater core for the heater.

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-- Remove the bolt -2- and the screw-type clamp.

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-- Remove the bolt -1- and the nuts -arrows- and tie up the catalytic converter.

-- Remove bolts -arrows- and remove bracket.

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-- Place a cloth underneath to catch escaping coolant.

-- Loosen the hose clamp -1- and remove the coolant hose.

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

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

-- Use the :80-200 for removing the spiral clips in the following steps.

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

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

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

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-- Release and disconnect the connectors -3-.

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-- Open the locking mechanisms -arrows- for the cable guide -1-.

-- 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-.

Manual Transmission

-- Remove the selector mechanism from the transmission. Refer to SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

-- Remove the clutch slave cylinder. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (0CG) and CLUTCH MECHANISM (02Q, 02QA) .

Automatic Transmission

-- Remove the selector lever cable, the Mechatronic connector and all brackets from the transmission. Refer to TRANSMISSION, REMOVING AND INSTALLING (02Q, 02QA) , TRANSMISSION, REMOVING AND INSTALLING (0CG) or TRANSMISSION, REMOVING AND INSTALLING (0AF) .

Continuation For All Vehicles

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-- Disconnect the breather line -arrow-.

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

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

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

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-- 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 bolt -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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-- Disconnect the connector -1- on the Oil Level Thermal Sensor -G266-.

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-- Disengage the wire from the bracket -2-.

-- Remove the left and right coupling rod nuts -arrow- on the stabilizer bar.

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-- Remove the bolts -1, 2 and 3- and the pendulum support.

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-- Remove the bolts -arrows- and remove the right drive axle heat shield.

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-- Remove the left and right nuts -arrows- for the ball joint.

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-- If equipped, remove the nut -arrow- from the Left Front Level Control System Sensor -G78-.

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-- Disengage the left and right ball joint from the transverse link.

-- Remove the left and right drive axle from the transmission and tie them up. Refer to DRIVE AXLE .

NOTE:

Be careful not to damage the protective coating on the drive axle.

-- Tilt the left suspension strut outward and support it with the :2024A/1 as shown in the illustration.

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-- Secure the pin and ball joint using the retainer -arrow- and nut -1-.

-- Fasten the right ball joint -2- to the transverse link -1- with the nut -arrow- as shown.

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-- Mount the T10497/2 on the housing rib of the cylinder block as shown.

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-- Position the T10497 with Pins T10497/1 on the cylinder block.

-- Install the bolt -1- through the hole "B" on the :T10497 and tighten to 20 Nm.

-- Attach the :T10497/3 to the :T10497 and tighten the bolt -1- to 20 Nm.

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-- Install the :VAS6931 on the :T10497 and slightly lift the engine/transmission assembly.

-- Use a commercially available step ladder to remove the subframe mount bolts.

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

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-- Remove the bolts -2- completely.

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NOTE:

Risk of damaging the vacuum lines or wires as well as the engine compartment.

Make sure all the vacuum lines or wires between the engine, the transmission, the subframe and the body are loosened.

Carefully guide the engine/transmission assembly with the subframe out of engine compartment when lowering.

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

-- Slightly lower the engine/transmission assembly.

-- Then push the transmission side of the engine/transmission assembly forward and then continue to lower it.