Engine, Removing
Engine, Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• Drained coolant must be stored in a clean container for disposal or reuse.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor Lift Table (VAS 6131 A) with Support Set (VAS 6131/10) as well as Supplementary Set (VAS 6131/11), (VAS 6131/13) and qty. 3 (VAS 6131/10-2)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (VAS 6362)
• Counterhold Tool (T10172) with (T10172/8)
• Ball Joint Puller (T10187)
Procedure
- On a vehicle with air suspension, activate vehicle lift mode.
There is a risk of injury because the fuel is under very high pressure.
• Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.
- Reduce fuel pressure in high pressure area.
Risk of destroying electrical components.
• Observe measures when disconnecting battery.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
• Place the selector lever in the "N" position and release the electromechanical parking brake before disconnecting the battery so that the driveshaft can still move freely.
- Position driver's seat as far back and up as possible using the full seat adjustment range.
- Switch off ignition.
- Grasp under the seat and release retaining clips on rear side of cover - 1 - in direction of - arrow A -.
- Then remove cover in direction of - arrow B - from driver's seat console.
- Pry the cover - 1 - out of the floor covering using a (80 - 200).
- Raise the floor covering - 2 - slightly in the Ground (GND) cable area.
- Remove nut - 3 - and remove Ground (GND) cable - 4 - from Ground point.
- Discharge refrigerant circuit.
- Extract power steering fluid from the reservoir using the (V.A.G 1782).
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• To reduce pressure, cover coolant reservoir cap with cloth and carefully open.
- Open the cap on the coolant reservoir.
- Remove both front wheels.
- Remove screws and remove front - 1 - and rear - 2 - noise insulation.
- Remove left and right front wheel housing liners..
- Place (VAS 6208) under engine.
- Remove drain plug - 1 - on map controlled engine cooling thermostat (F265) and allow coolant to drain.
• Ignore item - 2 -.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Lift the clamp to remove the lower coolant hose - arrow - and let the coolant drain.
- Remove coolant hoses from coolant pipes - arrows - and drain remaining coolant.
- Pull rear engine cover off - arrows -.
- Pull front engine cover off - arrows -.
- Remove cover over radiator - arrows -.
- Disconnect coolant hose - 1 -.
- Disconnect vacuum hose - 2 - to Evaporative Emission (EVAP) canister purge regulator valve (N80) by pressing release button.
- Free up vacuum hose.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
- Disconnect fuel supply line - 3 - at distribution piece.
- Disconnect electrical connector - 2 - at Mass Air Flow (MAF) sensor 2 (G246).
- Remove left air guide hose - 1 - from air duct.
- Release retaining clips - 3 - and remove upper left section of air filter housing.
- Open the cover over the terminal 30 wire junction 2 (TV22) - arrow -.
- Remove the bolts - 1 - for the battery jump start terminal (U6) and free up the electrical wire.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Remove hose - arrow - from power steering fluid reservoir.
- Separate the electrical connector - 1 -.
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Remove refrigerant lines - 2 - and - 3 - from A/C compressor.
- Seal open lines and connections with clean plugs from the (VAS 6122) to prevent dirt and moisture from entering.
- Disconnect electrical connector - 1 - at Engine Coolant Temperature (ECT) sensor (on radiator) (G83).
- Lift the retaining clip - 2 - and remove the upper coolant hose from the radiator.
- Remove coolant hose - arrow - to radiator from right coolant pipe.
- Remove air guide hose - arrow - from connecting hose to Secondary Air Injection (AIR) combi-valves.
- Unclip front differential breather line - arrow - from brake system vacuum pump (V192).
- Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
- Disconnect electrical harness connector - 4 - at Mass Air Flow (MAF) sensor (G70).
- Remove right air guide hose - 3 - from air duct.
- Release retaining clips - 2 - and remove upper right section of air filter housing from lower section.
Vehicles with air suspension:
• If necessary, remove electrical connector for Heated Oxygen Sensor (HO2S) 2 (G108) from bracket at right strut tower for better access.
- Press circlip - 1 - forward from hose coupling.
- Press release ring - 2 - down - arrows - and remove vent hose - 3 - from upper section of air filter.
All Vehicles
- Remove coolant hose - arrow - from coolant reservoir.
- Disconnect vacuum hose - arrow - to suction jet pump.
- Remove electrical connectors - 1 to 4 - from bracket on right strut tower.
- Disconnect electrical connectors and free up electrical lines.
- Remove the windshield wiper arms - 1 - and - 3 -.
- Remove rubber seal - 5 - and remove plenum chamber cover - 4 -.
The plenum chamber cover could be damaged.
• To prevent the cowl grille - 2 - from tearing when removing, coat the transition between the windshield and cowl grille with soapy water and pull the grille up vertically out of the fastening strip starting at the edge of the window.
- Carefully remove plenum chamber cover - 2 - from retainers on windshield.
- Remove cover for E-Box in plenum chamber - arrows -.
- Disconnect electrical connectors - 1 to 3 - at E-box plenum chamber connector station.
- Free up the wiring harness.
- Remove Ground (GND) connection - 2 -.
- Remove engine control module - 1 -.
- Free up electrical wiring harness to engine.
- Remove screws - arrows - and remove partition at left rear in engine compartment.
- Remove screws - arrows - and remove partition at right rear in engine compartment.
- Loosen upper control arm nut a few turns and pull joint off with (T10187).
- Completely remove upper control arm nut.
- Repeat procedure on opposite side of vehicle.
- Disconnect electrical connectors - arrow - at left and right on front speed sensors.
- Remove wiring harness bolts - arrows -.
- Remove brake caliper bolts - 1 -.
• Do not change brake line bend shape.
- Engage brake caliper in wheel housing with wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Repeat procedure on opposite side of vehicle.
- Disconnect lower threaded connection - 2 - at left and right on stabilizer bar.
- Remove nuts from bolts - 1 - at left and right on strut.
• Bolts - 1 - are removed later.
- Remove bolts - arrows - at transfer case/rear driveshaft connection.
- Counterhold with the (T10172) with (T10172/8).
- Slide driveshaft back to rear final drive; CV joints can move axially.
- Remove bracket for noise insulation - arrows -.
Danger of damaging the decoupling element.
• Decoupling element must not be bent more than 10°.
• Do not load decoupling element on cable.
• Do not damage wire mesh at decoupling element.
- Disconnect exhaust system at clamping sleeves - 1 - and - 2 -.
- Remove exhaust system bracket at left and right from longitudinal members - arrows -.
- Remove selector lever cable heat shield - arrows -.
- Press the selector lever cable ball head - 2 - off the selector shaft lever using the (80 - 200).
- Remove securing clip - 1 - and remove selector lever cable from transmission.
• Do not bend or kink selector lever cable.
- Disconnect electrical connector - arrow - at steering gear.
- Remove heat shield - A - from steering gear.
• Separate universal joint from steering gear only when front wheels are in straight ahead position.
• Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape.
- Remove universal joint bolt - B -.
- Press universal joint off of steering gear.
- Place the (V.A.G 1782) under the engine.
- Disconnect hydraulic line - 1 - to power steering cooler at left of lock carrier.
• Ignore item - 2 -.
• Observe the rules of cleanliness for working on automatic transmissions.
- Remove bolt - arrow - and disconnect ATF-lines from ATF thermostat.
- Remove Ground (GND) connection - 1 - from right longitudinal member.
- Disconnect electrical connectors - 1 to 3 - for automatic transmission 09D.
To separate engine from transmission after remove engine/transmission assembly:
- Remove ATF line - 1 - from transmission.
- Remove the 3 lower engine/transmission connection bolts - 2 to 4 -.
Prepare scissor lift platform:
- Equip (VAS 6131) with (VAS 6131/10) as well as (VAS 6131/11) and (VAS 6131/13) as follows:
- Install attachments on scissor lift table by hand first.
- Place scissor lift platform (VAS 6131) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Guide scissor lift table under engine/transmission assembly.
- Position the support elements from the (VAS 6131/10) and (VAS 6131/11) on the front of the subframe as illustrated.
- Make sure that the threaded spindles are completely screwed in.
- Position the support elements from the (VAS 6131/10) and (VAS 6131/13) on the engine carrier as illustrated.
- Position the support elements from the (VAS 6131/13) on the suspension struts as illustrated.
- Position the support elements from the (VAS 6131/10) on the rear of the transmission as illustrated.
- Position the support elements from the (VAS 6131/10) on the left and right of the subframe as illustrated.
- Twist spindles of attachments upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on scissor lift platform (VAS 6131).
- Remove bolt - 1 - at left and right.
• The threaded connection - 2 - has already been disconnected.
- Mark installation position of subframe, engine carrier and transmission carrier to longitudinal members using a felt-tip marker.
- Remove bolts - 1 to 4 - in diagonal sequence and in stages.
• Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.
• While lowering, carefully guide engine/transmission assembly out of engine compartment in order to prevent damage.
• Carefully guide suspension struts onto longitudinal members.
- Lower engine/transmission subassembly downward.
- Push scissor lift platform (VAS 6131) with engine/transmission subassembly under vehicle.