Part 1
Engine, Removing
Special tools, testers and auxiliary items required
• Adapter (10 - 222 A /7)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Sling (2024 A)
• Lifting Tackle (3033)
• Hose Clamps Up to 25 mm Dia. (3094)
• Counter Support (3145)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Shop Crane (VAS 6100)
• Lift Arm Ext./Workshop Hoist (VAS 6101)
• Engine Bung Set (VAS 6122)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Lifting Eye for Removing Transmission (T40137)
Procedure
• The engine with transmission is removed upward.
• During installation, all cable ties must be installed at the same location.
CAUTION!
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.
- Remove the passenger seat.
- Install protective body covers. Refer to => [ Protective Body Covers, Installing ] Procedures.
- Remove the left - 1 - and right - 3 - engine compartment trim.
- Remove the engine cover - 2 -.
- Bring the rear lid into the service position.
- Remove the left and right side panel cover.
- Empty coolant circuit.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
- Remove the rear - 1 - and front - 2 - noise insulation.
- Remove the left and right rear wheels.
- Remove the left and right rear wheel housing liners.
- Remove the rear impact absorber.
- Remove left and right tail lamp assemblies.
- Remove the rear lid rack.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- With the ignition switched off, disconnect the battery ground (GND) - arrow -.
CAUTION!
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 coolant reservoir cap.
• Collect escaping coolant in a clean container for disposal or reuse.
- Place (VAS 6208) under engine.
- Remove the drain plug - arrow - on the suction module and drain the coolant.
- Remove the drain plug - arrow - on the coolant thermostat housing and drain the coolant.
- Loosen the hose clamps - 1, 2 and 3 - and remove the coolant hoses.
- Free up the coolant hose - arrow -.
- Drain engine oil.
- Place the (V.A.G 1782) under the disconnection point.
- Remove the bolts - 1 - and - 2 - and remove the oil lines.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove the driveshaft.
- Remove the nut - 2 - by counterholding the drive-through shaft flange - 1 - using the (3145), then remove the flange.
• If it is difficult to remove the drive-through shaft flange, use a commercially available puller.
CAUTION!
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Depending on the date of manufacture, either remove the nut - 1 - or cut the cable tie.
- Remove the bolt - 2 - and disconnect the refrigerant line.
- Remove the bolt - arrow - and remove the refrigerant line from the reservoir and place it in the engine compartment.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove engine bracket left and right bolts - arrows -.
- Place the (V.A.G 1782) under the disconnection point.
- Remove the bolts - 2 - and disconnect the oil line from the oil tank.
- Remove the ground (GND) cable bolt - 1 -.
CAUTION!
There is a risk of contamination.
• There is still oil in the oil line.
- If the engine and transmission should be separated after removing them, remove bolt - 9 - and nuts - 1, 7 and 8 - from the engine to transmission connection.
- Place the (V.A.G 1782) under the disconnection point.
- Disconnect the power steering hydraulic fluid line at the threaded connection - 1 -.
- Remove the clamp screw - 2 -.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Place the (V.A.G 1782) under the disconnection points.
- Remove the bolt - arrow - and disconnect the transmission fluid lines from the transmission fluid thermostat.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove the left and right drive axles from the transmission flange shafts - arrows -.
- Loosen the hose clamps - 2 - and - 4 -.
- Remove the air filter housing bolts - arrows -.
- Remove the boots - 1 - and - 6 - from the air filter housing.
- Disconnect the electrical connectors:
3 on the mass airflow sensor 2 (G246)
5 at mass air flow sensor (G70)
- Remove the air filter housing and mass airflow sensors.
- Disconnect brake booster vacuum hose - 1 -.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Ignore - 2 -.
CAUTION!
Risk of injury from fuel.
• To reduce residual pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.
- Remove the fuel supply line - 1 - and move it to the side.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Ignore - 2 -.
- Remove the left and right nuts - 1 - and the bolt - 2 - and then remove the heat shield.
- Remove the left and right nut - 1 - and bolt - 3 -.
- Free up the vacuum line - 2 -.
- Free up the wiring harness - arrow -.
- Pull the heat shield off the threaded pin just a little.
- Disconnect the connector - 1 -.
- Remove the nuts - arrows - accessible from above.
- Press the release buttons and remove the secondary air hoses - arrows -.
- Remove the nut - 1 -, remove the right secondary air injection pump and free up the wiring harness.
- Loosen the clamp - 1 - on the left exhaust system tract, tilt it outward with the spring element - arrow - and remove the clamp.
- Repeat the procedure on the other side of the vehicle.
• Two people are needed to remove the muffler.
- Remove the nut - arrow - on the heat shield.
- Remove the vacuum hose - 1 - from the exhaust flap vacuum actuator and free it up.
- Remove the bolts - 2 - and - 4 - and remove the socket - 3 -.
- Repeat the procedure on the other side of the vehicle.