Engine, Removing

Special tools and workshop equipment required 

• Engine Sling - Engine Bracket: 2024A/1  for the Engine Sling : 2024A 
• Pry Lever : 80-200 
• Engine and Gearbox Jack : VAS6931 
• Step ladder such as Step Ladder : VAS5085 
• Engine Bung Set : VAS6122 
• Shop Crane - Drip Tray : VAS6208 
• Hose Clip Pliers : VAS6362 
• Engine/Gearbox Jack - Engine Support : T10359A 
• Protective eyewear
• Protective gloves

Mandatory Replacement Parts 

• Bolts - Transmission mount bracket
• Bolts - Engine mount bracket
• Bolts - Pendulum support
• Bolts - Driveshaft
• Nuts - Ball joint
• Nuts - Front exhaust pipe with catalytic converter
• Gasket - Front exhaust pipe with catalytic converter
• O-rings - Coolant lines

Procedure 

-- Remove the cap -arrow- from the coolant reservoir.

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

-- Disconnect the connector -3- from the Mass Airflow Sensor -G70-.

-- Remove the hose -4-.

-- Remove the air guide hose by loosening the hose clamp -2-.

-- Remove the bolts -1 through 5- and then remove the air filter housing.

-- Remove the left and right front wheels. Refer to WHEELS, TIRES, WHEEL ALIGNMENT .

-- Remove the noise insulation. Refer to Noise Insulation, Removing And Installing .

-- Remove the left and right wheel spoilers. Refer to Spoiler, Removing And Installing .

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

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

-- Remove the nut -2- and the bolt -3-.

-- Loosen the clamp -1- and remove the air guide pipe.

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

-- Open the clamp -1- and remove the air guide hose.

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

-- Place the :VAS6208  under engine.

-- Open the clamp, drain the coolant and then remove the left lower coolant hose -arrow- from the radiator.

-- Remove the lower coolant hose to the After-Run Coolant Pump -V51- by loosening the hose clamp -arrow- and allowing the coolant to drain.

-- To release the tension on the ribbed belt, move the tensioner clockwise -arrow-, remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tensioner.

-- Remove the ribbed belt.

-- Disconnect the connector -1- on the A/C Compressor Regulator Valve -N280-.

-- Remove A/C compressor bolts -arrows-.

-- Remove the A/C compressor with the refrigerant lines connected and tie it up on the right side.

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

-- Remove the vacuum hose -arrow- from the brake booster.

-- Remove the heat insulation sleeve.

-- Life the clamps -arrows- and remove the coolant hoses from the heater core.

-- Remove the connector -arrow- for the Heated Oxygen Sensor -G39- from the bracket, disconnect it and free up the wire.

-- Disconnect the hose -arrow- for the leak detection.

-- Remove the coolant hoses by loosening the hose clamps -1 and 2-.

There is a risk of injury due to the fuel being under pressure.

The fuel system is under pressure. Injuries are possible from fuel spraying out.

Before opening the fuel system:

-- Wear protective eyewear.

-- Wear safety gloves.

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

-- Press the release ring and disconnect the fuel hose -2-.

-- Press the release buttons and disconnect the hose -1- from the EVAP canister.

-- Lift the clamps -1 and 2- to remove the left upper coolant hoses from the radiator.

-- Remove the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Remove the Throttle Valve Control Module -J338-. Refer to Throttle Valve Control Module -J338-, REMOVING AND INSTALLING .

-- Release the cable grommet -1- for the engine wiring harness -arrows- and remove it upward.

-- Open wiring router bracket -arrows-.

-- Disconnect the connectors -1- and free them up.

-- Open the wiring guide bracket below -2- in the direction of -arrow-.

-- Remove the engine control module wiring harness out of the wiring guide and lay it on the engine.

-- Disconnect the connector -arrow- on the lower left longitudinal member.

-- Disconnect the connector -2- from the Charge Air Pressure Sensor -G31- and free up the wire.

-- Remove E-box cover by slide both latches in the direction of -arrow-.

-- Remove the nut -arrow- and then remove and free up the terminal 30 wire from the engine compartment E-box.

Vehicles with a Manual Transmission

-- Remove the bolts -arrows- and set the cable bracket with the cables to the side.

-- Pull the safety mechanism all the way to the front in the direction of -arrow 1- and then lock it to the left in the direction of -arrow 2-.

-- Push the shift relay lever forward in the direction of -arrow 3- and remove the selector cable from the retainer.

-- Remove the lock washer -3- for the shift cable from the gearshift lever -1- and remove the shift cable -2- from the pin -arrow-.

-- Disconnect the connector -2-.

-- Push back the B+ terminal protector -1- and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -3- and remove the ground wire.

-- Disconnect the connectors -1 and 2-.

-- Place a lint-free cloth under the bleeder.

-- Remove the clip -arrow- all the way and remove the pipe -A- from the bleeder.

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

Vehicles with S tronic Transmission 

-- Disconnect the connector -2-.

-- Push back the B+ terminal protector -1- and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -3- and remove the ground wire.

-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Disconnect the connector -4- by turning twist lock counter-clockwise.

-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the :80-200  .

-- Release the retainers -arrows- and free up the selector lever cable.

Vehicles with Automatic Transmission 

-- Disconnect the connectors -1 and 2- and free up the wires.

-- Loosen the clamp -2- and remove the coolant hose.

-- Remove the bolts -1 and 5- and nuts -3 and 4- and push the bracket with the ATF cooler to the side.

-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the :80-200  .

-- Release the retainers in the direction of -arrows- and free up the selector lever cable.

-- Disconnect the connector -2-.

-- Remove the selector lever cable -1- from the bracket -2- on the transmission.

-- Disconnect the connector -3- by sliding the retainer back and pressing the release down.

-- Remove the cap -4-.

-- Remove the terminal 30/B+ wire -1- from the starter.

-- Remove the nut -2- and free up the ground cable.

-- Disconnect the connectors -1 and 2- from the transmission and free them up.

-- To discharge static electricity, touch vehicle Ground (GND) with hand (without gloves).

All Vehicles 

-- Loosen the bolts -arrows- on the engine mount approximately 2 turns.

-- Loosen the bolts -arrows- on the transmission mount approximately 2 turns.

-- Disconnect the connector -1- on the Oil Level Thermal Sensor -G266-.

-- Unclip bracket -2- for electrical wiring to Oil Level Thermal Sensor -G266- from subframe.

-- Remove the left and right nuts for the coupling rod on the stabilizer bar. Refer to COUPLING ROD, REMOVING AND INSTALLING and STABILIZER BAR, REMOVING AND INSTALLING .

-- Remove the bolts -1, 2 and 3- and remove pendulum support.

-- Remove the left and right nuts -arrows- for the ball joint.

-- Remove the nut on the Left Front Level Control System Sensor -G78- bracket, if equipped.

-- Disengage the left and right ball joint from the transverse link.

-- Remove the left and right drive axle from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the left drive axle.

-- Tilt the left and right suspension strut outward and support it with the :2024A/1  as shown in the illustration.

Vehicles with AWD 

-- Remove the bolts -arrows- and remove the heat shield -1-.

-- Mark position of flexible disc and the bevel box flange to each other for reinstallation.

-- Remove the bolts -arrows- on the driveshaft flexible disc connection from the bevel box by counterholding at the triangle flange with a lever.

-- Press the engine/transmission assembly slightly forward (toward the front end) and remove the driveshaft from the bevel box.

Continuation for All Vehicles 

-- Remove the bolts -arrows-.

-- Move the generator -4- with the wires connected to the right side of the vehicle.

-- Disconnect the connector -1-.

-- Pry off the protective cap -2- and remove the nut for the terminal 30/B+ -3-.

-- Remove the generator upward.

-- Remove the nuts -arrows- on the front exhaust pipe connection with the catalytic converter from the turbocharger.

-- Secure the catalytic converter to the rear.

-- Remove the bolt -2- on the bracket for the After-Run Coolant Pump -V51-.

-- Fasten the :T10359A  with the bolt -1- to 20 Nm on the cylinder block at the threaded hole for the After-Run Coolant Pump -V51-.

-- Install the :VAS6931  on the :T10359A  and slightly lift the engine/transmission assembly.

-- Remove the engine mount bolts -arrows- completely.

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

-- Lower the engine/transmission assembly a little.

-- Then move the transmission side of the engine/transmission assembly forward and lower it a little more.