Engine, Removing: Procedure

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

NOTE:

The engine is removed downward together with the transmission.

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

Seal the disconnected fuel and ventilation lines to prevent dirt from getting into the system.

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

If the engine oil must be drained because of work performed on the removed engine, it should be performed with the engine installed. If engine hangs on the :T03001 , the engine is not in the installation position and less engine oil flows out.

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 order 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 some components cannot be removed or can only be removed with great difficulty. Determine which parts are faulty before removing so that they can replaced while they are removed.

To prevent damage to the removed components, use the :VAG1698 as storage.

CAUTION:

Note the following whenever working inside the engine compartment due to limited space:

Route all lines and cables in their original locations.
Make sure that there is sufficient clearance to all moving or hot components.

-- Check the DTC memories on all control modules. Refer to Vehicle Diagnostic Tester.

-- Remove the complete air filter with the connecting hose to the Throttle Valve Control Module -J338-. Refer to OVERVIEW - AIR FILTER HOUSING .

-- Remove the bracket from the air filter -Item 17- AIR FILTER .

-- Remove the E-box cover inside the engine compartment -arrows-.

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With the ignition switched off, disconnect the ground cable from the battery. Refer to BATTERY .

-- Disconnect the connector -3- from the engine control module and free up the electric engine wiring harness. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

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-- Disconnect the generator cable from the fuse panel -arrow-.

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-- Disconnect the connector -4-, open the locking mechanism and lay the engine wiring harness -3- on the engine.

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-- Disconnect the ground cable -1- and the starter connections -2 and 5-.

-- Disconnect the heated oxygen sensor connectors on the bulkhead. Move the electrical wiring harness to the side.

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-- Disconnect all connectors from the transmission.

-- Remove/disconnect all necessary wires from the engine/transmission and free them up.

-- Disconnect selector lever cable from the transmission.

WARNING:

The fuel line is under pressure.

Fuel poses a risk of injury to the eyes and skin.

Wear protective eyewear and protective clothing to avoid injury and contact with skin. Place a cleaning cloth around the connection point before loosening hose connections. Carefully open the connection point to release the pressure.

-- Disconnect the fuel supply line -1- and the bleeder line -2-. Refer to CONNECTOR COUPLINGS .

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-- Disconnect the vacuum line from the brake booster and intake manifold.

-- Seal the lines so that the fuel system is not contaminated by dirt etc.

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

WARNING:

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce the pressure by covering the coolant reservoir cap with a cloth and carefully opening.

-- Open the cap on the reservoir and then close it again to release the pressure in the coolant system.

NOTE:

The vehicle has a manual hood support that is attached to the lock carrier.

-- Perform a service position. Refer to LOCK CARRIER .

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

-- Remove the wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Disconnect the connector from the Oil Level Thermal Sensor -G266-.

-- Remove the Oil Level Thermal Sensor -G266- wire holder from the subframe and lay it on the subframe.

-- Remove the wires and brackets from the front transmission cover -arrows- (two M6 nuts).

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-- Move the wire near the transmission cover upward and tie them secure.

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

-- Remove the coolant hoses from the heat exchanger -arrows-.

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-- Open the clip -arrow-.

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-- Remove the upper radiator coolant hose -1-.

-- Remove the bolt -2- and move the washer fluid reservoir filler neck forward -1-.

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-- Remove the connector -3-.

-- Remove the bolts -5- and place the coolant expansion tank -4- on top of the engine with the hoses connected.

NOTE:

Loosen the bolts on the engine mount and transmission mount one turn.

WARNING:

Refrigerant can cause serious injury.

Do not open the A/C system refrigerant circuit.

So that it is possible to remove the engine without opening the refrigerant circuit:

-- Remove the A/C compressor from the auxiliary components bracket. Refer to A/C COMPRESSOR .

CAUTION:

Risk of damaging the refrigerant lines and hoses.

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

-- Secure the A/C compressor to the bumper cover using a :T10038 and a suitable mat -A-. Slide :T10038 as far as possible on to mounting bolt -arrow-.

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-- Remove the heat shield above the right drive axle.

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-- Remove the both drive axles. Refer to DRIVE AXLE .

CAUTION:

Danger of causing damage to the decoupling element.

Do not bend the decoupling element more than 10°.
Do not stretch the decoupling element.
Do not damage the wire mesh on the decoupling element.

-- Remove the front exhaust pipes from the exhaust manifolds -arrows-.

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-- Remove the rear clamping sleeve and suspended mounting from the front exhaust pipe. Remove the front exhaust pipe and oxygen sensors.

NOTE:

The oxygen sensors can remain installed.

-- Remove bolts -1 to 3- and remove pendulum support.

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-- Install the :T40074 in the :VAS6931 .

-- Remove the :T40074/1 from the :T40074 and attach it to the cylinder block with a nut -1-.

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-- Position the :T40074 on the engine as illustrated and install the :T40074/1 to the :T40074 -2-.

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-- Tighten the :T40074 with M10 x 25 bolts as shown on the exhaust side to approximately 20 Nm on the cylinder block -arrows-.

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-- Lift the engine and transmission gently using the :VAS6931 .

-- Remove the engine-side of the subframe mount from the engine bracket -arrows- from above.

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-- Remove the subframe mount on the transmission side from the transmission holder -arrows- from above.

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NOTE:

Use :VAS5085 to remove securing bolts.

Carefully guided engine with transmission, when lowering, to prevent damage to bodywork.

-- Carefully lower engine with transmission.