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/Gearbox Jack - Engine Support: T10359 A
Engine/Gearbox Jack - Pin: T10359/2
Engine/Gearbox Jack - Adapter: T10359/3
Securing element from the Transmission Support: 3282
Pry Lever: 80 - 200
Engine Bung Set: VAS6122
Protective Eyewear
Safety Gloves
Step Ladder

CAUTION:

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

Mandatory Replacement Parts

Bolts - Engine mounts
Bolts - Transmission mounts

NOTE:

The engine with transmission is removed downward. For this reason it is necessary to remove the subframe.

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 engine oil must be drained because of work performed on the removed engine, it should be performed with the engine installed. If the 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 rotor cover plates are just above the floor. This enables the most ergonomic work position regarding accessibility of components in the engine compartment.

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

Procedure

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

-- Remove the complete air filter with the connecting hose to the Throttle Valve Control Module -GX3-. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Disconnect the connector -1- from the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

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-- Remove the connectors -2 and 3- from the bracket and disconnect.

-- Free up the wires.

-- Release the retainers in direction of -arrows- and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver -arrow-, remove the cover -1- for the engine compartment E-box upward.

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-- Remove the nut -arrow-, disconnect and free up the wires.

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-- Pry the selector lever cable -1- off the selector lever -2-, for example, using an open end wrench.

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-- Remove the connector -6- from the Multifunction Transmission Range Switch -F125- and free up the wire on the bracket.

-- Remove the bolts -5- from the cable bracket -4-. Do not remove the lock washer -3-.

-- Disengage the selector lever cable -1- from the clip -arrow-.

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NOTE:

Do not bend or kink the selector lever cable.

So that the cable is not damaged when removing and installing the transmission, secure the cable using for example a cable tie on a suitable location on the body.

-- Remove the connector from the transmission as follows. Push the retainer -1- in the direction of the arrow, open the bracket -2- and then remove the connector -3- from the transmission.

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-- Disconnect the connections from the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Remove the bolt -A- and remove the ATF lines -2- from the thermostat -1-.

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Ignore the bolts -B-.

-- Remove the connectors -1 and 2- from the bracket and disconnect them. Then free up the wires.

Fig 1: Heated Oxygen Sensors

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-- Remove all remaining wires necessary from engine/transmission and set aside.

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CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Disconnect the fuel supply line -1- and vent line -2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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

-- Remove the vacuum line on the brake booster, on the intake manifold and on the vacuum pump.

Fig 2: Identifying Coolant Reservoir Cap

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CAUTION:

The cooling system is under pressure when the engine is warm. There is a 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 cap on the expansion tank -arrow- and then close it again to release the pressure in the coolant system.

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

-- Remove the front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the both drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Disconnect the connector -1-.

Fig 3: Component Location Engine Coolant Temperature Sensor

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

-- Release the clamps -arrows- and remove the coolant hoses -1-.

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-- Open the clip -arrow-.

Fig 4: Identifying Upper Coolant Hose

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

-- Disconnect the connector -1-.

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-- Release the catches with a screwdriver in direction of -arrow-. Place the coolant expansion tank with hoses on the engine.

-- Loosen the bolt -arrows- for the engine mount approximately 1 turn.

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-- Loosen the bolt -arrows- for the transmission mount approximately 1 turn.

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

-- Loosen the hose clamps -arrows- and remove the left charge air hose -1-.

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-- Disconnect the connector -1- for the radiator fan, to do this push the clip in direction of -arrow A- and push the retainer down.

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-- Push the left and right locking ring -B- for the fan shroud evenly on both sides. Disengage the fan shroud and remove downward from the radiator.

-- Loosen the hose clamp -arrow- and remove the right charge air hose -1-.

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-- Seal the open lines and connections with clean plugs from the : VAS6122 .

-- Cover the radiator with the : VAS531003 .

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

Fig 5: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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-- Pivot the tensioner clockwise -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 .

Fig 6: Identifying A/C Compressor Components

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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-.

-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses connected and tie up to the right side. While doing so, do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the nuts -2-.

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-- Loosen the clamping sleeve -arrow- and push it toward the rear.

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-- Remove the catalytic converter with the front exhaust pipe.

-- Remove bolt -arrow- and push the bracket for the wiring harness to the side.

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-- Install the : T10359/3 , as shown, on the : T10359A .

Fig 7: Identifying Engine/Gearbox Jack Engine Support

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

-- Place the : T10359 in the : VAS6931 .

-- Install the : T10359 on the cylinder block. Tighten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 8: Identifying Engine Support

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-- Secure the engine with the support element -B- and lift the engine with the transmission.

-- Remove the engine mount bolts -arrows-.

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-- Remove the bolts -arrows- for the transmission mount.

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-- Carefully drain the engine/transmission assembly while doing so check is all vacuum lines or wires between the engine, transmission and body are separated.

Fig 9: Identifying Engine Jack

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