Engine, Removing: Procedure

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CAUTION:

The cooling system may be under pressure. 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 suitable towel and carefully opening it.

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the front section of the left and right front wheel housing liners. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Disconnect the connector -1-.

Fig 1: Component Location Engine Coolant Temperature Sensor

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-- Place the Shop Crane - Drip Tray :VAS 6208 underneath.

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

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

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

-- Remove the air duct from the lock carrier. Refer to AIR DUCT ON LOCK CARRIER, REMOVING AND INSTALLING .

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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-- Engine compartment battery: remove the battery tray -1-. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Luggage compartment battery: remove the air filter housing mount.

-- Disconnect the vacuum hose -2-.

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-- Press the release button on the vacuum hose -1- and remove the hose from the vacuum pump.

Vehicles without Parking Heater:

Fig 2: Identifying Heater Core Hoses

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

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

Vehicles with Parking Heater:

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-- Loosen the hose clamp -1-, lift the clamps -arrows- and remove the coolant hoses.

Continuation for All Vehicles:

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-- Remove the connector -2- from the bracket, disconnect it and free up the wire.

-- Remove the connector -arrow- for the Oxygen Sensor 1 After Catalytic Converter -GX7- from the bracket, disconnect it and free up the wire.

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-- Remove the bolt -1- and the screw-type clamp.

Fig 3: Catalytic Converter Tightening Specification and Sequence

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-- Loosen the bolt -2- and disengage the catalytic converter upward and push to the side. (Shown with the engine removed.)

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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.

-- Place a cloth under the separating point to catch any escaping fuel.

-- Disconnect the fuel hose -1- and remove the hose -2- for the EVAP system. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Open the tab -3- and free up the hoses.

-- Remove the screw -arrow-, if applicable.

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-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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

Fig 4: Identifying Clamp And Upper Left Coolant Hose

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NOTE:

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

Fig 5: Free Electrical Wiring Up To Generator Using 80-200

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

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-- Remove the connectors -2 and 3- from the bracket and disconnect them and then free up the wires.

-- Remove the nut -4- and free up the ground wire.

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- To discharge static electricity, touch a ground by hand (without gloves).

-- Do not touch connector terminals in the transmission connector with hands.

-- Disconnect the connector -2- for the Dual-Clutch Transmission Mechatronic -J743- by turning the twist lock counter-clockwise.

-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to the appropriate service information .

-- Loosen the bolts -arrows- for the transmission mount approximately two turns.

Fig 6: Identifying Bolts

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-- Loosen the bolts -arrows- for the engine mount approximately two turns.

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

Fig 7: Removing Change Air Hose

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-- Disconnect the radiator fan connector -1- by sliding the retainer back in the direction of the arrow -A- and pressing the release downward.

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-- Press the left and right fan shroud -B- locking tabs evenly. Disengage the fan shroud and remove downward from the radiator.

-- Loosen the hose clamp -1- and -2- and remove the right charge air hose.

Fig 8: Identifying Clamps

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-- Seal the open lines and connections with clean plugs from the Engine Bung Set :VAS 6122 .

-- Cover the radiator with the Protective Mat :VAS 531003 .

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-- Loosen the hose clamps -1 and 2- and remove the air duct hose.

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Vehicles with Parking Heater:

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-- Loosen the clamp -1-, remove the bolt -2- and remove the parking heater muffler.

Continuation for All Vehicles:

Fig 9: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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

-- 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 Locking Pin :T10060A .

Fig 10: 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 attached and tie up to the right side. While doing so, do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the left and right drive axles from the flange shafts. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the drive axles to the rear.

NOTE:

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

-- If equipped, release the connector for the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- -a- and remove the connector -b-.

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Vehicles with Front Axle Differential Lock

Fig 11: Locating Axle Differential Lock Control Module Connector

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-- Disconnect the connector -arrow- for the Differential Locks Control Module -J647-.

AWD Vehicles:

Fig 12: Driveshaft Heat Shield

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-- Remove the bolts -A- and -B- on the bevel box and remove the heat shield -1-.

-- Mark the position of the driveshaft with the flexible disc to the bevel box output flange -arrows-.

Fig 13: Mark Position Of Driveshaft

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-- Remove the driveshaft from the bevel box -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

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-- To loosen or tighten the driveshaft, counterhold at the rear final drive if necessary.

Fig 14: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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-- Secure the Support Bridge :T10323 with a bolt in the inside rear threaded hole for the subframe.

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-- A subframe bolt is suitable for this.

-- Place a cloth -A- on the Support Bridge and place the driveshaft on it.

Continuation for All Vehicles:

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

-- 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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-- Fasten the Adapter T10359/3 on the Engine/Gearbox Jack - Engine Support :T10359 A as shown.

Fig 15: Identifying Engine/Gearbox Jack Engine Support

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

-- Insert the Engine/Gearbox Jack - Engine Support :T10359 A in the Engine and Gearbox Jack :VAS 6931 .

-- Position the Engine/Gearbox Jack - Engine Support :T10359 A on the cylinder block. Tighten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 16: Identifying Engine Support

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

-- Completely remove the engine mount bolts -arrows-.

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-- Completely remove the transmission mount bolts -arrows- completely.

Fig 17: Identifying Bolts

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-- Carefully lower the engine/transmission assembly. While doing so, check if all vacuum lines or wires between the engine, transmission and body are separated.

Fig 18: Identifying Engine Jack

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