Engine, Removing
Engine, removing
Note:
^ The engine is removed toward the front with lock carrier removed.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
^ Drained coolant must be stored in a clean container for disposal or reuse.
Work procedure
- On a vehicle with automatic transmission, shift the selector lever to position N.
CAUTION: Observe procedures for disconnecting battery.
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on sound insulation.
- Loosen quick-release fasteners - 1 - and - 2 - and remove front sound insulation.
- Remove quick-release fasteners - 3 - and remove rear sound insulation, if installed.
- Remove bracket for sound insulation - arrows -.
- Remove front bumper cover.
- Remove air guides from in front of charge air coolers at left and right - arrows -.
- Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
- Open drain plug - arrow - from lower left coolant hose and drain coolant.
- Disconnect lower coolant hose from radiator - arrow -.
- Remove air duct hose - 1 - to bottom of left charge air cooler.
CAUTION: The air conditioning refrigerant circuit must not be opened.
- Unhook refrigerant line from bracket - 2 -.
- Remove air duct hose - 1 - to turbocharger at bottom right.
- Remove air duct hose - 2 - to charge air cooler at lock carrier.
- Clamp hydraulic hoses to power steering system cooling coil using hose clamps 3094.
- Place old oil collecting and extracting device V.A.G 1782 underneath.
- Disconnect hydraulic hoses - arrows -.
Vehicles with automatic transmission:
Note: Observe the rules of cleanliness for working on automatic transmissions.
- Place old oil collecting and extracting device V.A.G 1782 underneath.
- Disconnect ATF lines at separation point.
- Remove bracket for ATF lines on engine.
All:
- Remove engine cover - arrows -.
- Remove bolts - arrows -.
- Remove air duct - 1 - and - 2 -.
- Disconnect coolant hose - 1 - at top of radiator.
- Disconnect electrical harness connector - 2 - for left and right airbag sensors on lock carrier.
- Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Free up electrical wiring.
- Separate left and right electrical connectors - 3 - of horns - 2 -.
Note: Ignore - Pos. 1 -.
- Remove bumper - arrows -.
- Remove left and right air guides at radiator - arrows -.
- Unclip Outside Air Temperature Sensor G17 - 2 - from bracket.
- Remove bolts - 3 - and - 4 - and remove power steering system cooling coil.
- Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.
CAUTION: The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrows - for the condenser.
Note: To prevent damage to condenser and to the refrigerant lines/hoses, make sure that the lines and hoses are not stretched, kinked or bent.
- Pivot condenser downward with lines connected.
- Remove bolts - arrows - at left and right side of bumper.
- Unhook cable for hood release at lock.
- Remove hood seal from lock carrier and fender edges.
- Remove bolts - arrows - at left and right impact absorbers.
Note: A second technician is required to remove lock carrier.
- Remove lock carrier and set aside so it cannot topple.
Note: Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning of direction can cause damage to the belt under operating conditions.
- Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
- Secure tensioning element using drift T40098.
- Remove ribbed belt.
- Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor G266.
- Remove oil pan bracket - arrow - for refrigerant line.
- Disconnect connector - 1 - for wiring to air conditioning compressor clutch solenoid.
CAUTION: The air conditioning refrigerant circuit must not be opened.
- Remove air conditioning compressor from bracket - arrows -.
Note: To prevent damage to condenser and to the refrigerant lines/hoses, make sure that the lines and hoses are not stretched, kinked or bent.
- Hang up air conditioning compressor and condenser with attached lines on right side of vehicle.
- Unfasten Ground (GND) cable - 1 -.
- Disconnect vacuum line to brake booster at bulkhead - 2 -.
- Disconnect EVAP hose - 3 -.
- Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -
- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.
- Disconnect electrical connector from Charge Air Pressure Sensor G31 - 1 -.
- Remove left charge air hose - 2 -.
- Remove right charge air hose - 1 -.
- Pull electrical connector - 1 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector) out from retainer
- Pull electrical connector - 2 - for Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector) out from retainer
CAUTION: Before opening a component of the high-pressure section, the fuel pressure must be released.
- Disconnect fuel line - arrow - (catch escaping fuel and plug open lines immediately).
- Disconnect coolant hoses to heater core on rear of engine.
- Remove windshield wiper arms.
- Remove cowl.
- Remove cover for E-Box in plenum chamber, by removing bolts - arrows -.
- Carefully pry off retainer bar with a screwdriver - arrow -.
- Unbolt electrical cable - 1 -.
- Disconnect electrical connectors - 2 to 4 - in E-box.
- Unclip fuse carrier - arrows -.
- Free up cable harness and lay it aside on engine with Engine Control Module (ECM) J623 connected.
- Unscrew threaded connections - 1 - of power steering pump through holes in belt pulley.
- Unscrew threaded connection - arrow - on backside of power steering pump.
- Disconnect connector - 1 and 2 - and free up cable.
- Separate intake hose - 3 - for air filter/turbocharger.
- Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
- Free up wiring harness on air filter housing and remove air filter housing - arrow-
- Remove Ground (GND) strap - arrow - from right longitudinal member.
- Remove heat shield - 1 - for right drive axle.
Note: Exhaust system decoupling element must not be bent more than 10°, otherwise it may be damaged.
- Loosen clamping sleeve - arrow - and push it rearward.
- Separate front exhaust pipe/catalytic converter - arrows -.
- Remove bolt - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.
- Disconnect connector - arrow - from Back-Up Light Switch F4 and free up cable to cable harness.
- From below, remove accessible threaded connections - 1 to 3 - and - 7 to 11 - of engine/transmission.
- Remove starter and set aside.
- Disconnect electrical connector - 3 -.
- Remove nut - 1 - for clamp.
- Remove nut - 2 - and remove electrical wiring.
- Remove starter.
- Mark installed position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.
Note: Depending on the engine version, different fastening holes are utilized.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Loosen upper nut on left engine mount several turns.
- Hook engine sling 2024 A onto engine and onto Shop Crane - Load Cap = 700 - 1200Kg VAS 6100 as shown in illustration.
Note: To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
CAUTION: Lifting hooks and alignment pins on the engine sling must be secured with securing pins.
- Remove last engine/transmission connecting bolt.
Note: Verify that all hose and line connections between engine and body have been disconnected.
- Lift engine until engine mount studs are free.
Lift floor jack until transmission is supported.
- Pull engine off from transmission and lift it forward and out of engine compartment.