Engine, Removing

Special tools and workshop equipment required 

• Pry Lever :80-200 
  Fig 1: Identifying Pry Lever

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• Engine Bung Set :VAS6122 
  Fig 2: Engine Bung Set

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• Shop Crane - Drip Tray :VAS6208 
  Fig 3: Identifying Drip Tray

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• Hose Clip Pliers :VAS6340 
  Fig 4: Hose Clip Pliers VAS6340

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• Hose Clip Pliers :VAS6362 
  Fig 5: Hose Clip Pliers

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• Engine and Gearbox Jack :VAS6931 
  Fig 6: Engine and Gearbox Jack VAS6931 or VAG1383A

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• Engine Holder Bracket :T03000A 
  Fig 7: Engine Holder Bracket

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• Commercially available Step Ladder
• Safety Gloves
• Protective Eyewear

Procedure 

• The engine is removed downward together with the transmission.
• During installation, all cable ties must be installed at the same location.

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

-- Discharge the refrigerant circuit. Refer to REFRIGERANT CIRCUIT, DISCHARGING .

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove the engine cover upward in direction of -arrows-.

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-- Remove the bolts -arrows- and air duct -1-.

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Vehicles with Version 1 Air Duct Hose:

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-- Remove the bolts -1- and remove the air duct hose -2- from the connections.

Vehicles with Version 2 Air Duct Hose:

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-- Loosen the hose clamp -1- and remove the air duct hose.

Continuation for All Vehicles:

-- Loosen the clamp -2- and remove the air duct hose.

-- Free up the transmission ventilation hose -4-.

-- Remove the air filter housing upward from the retaining pin.

-- Free up the wiring harness on the bracket -1- for the air filter housing.

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-- Remove the bolts -arrows- and remove the bracket for the air filter housing (example illustration above).

-- Vehicle with particulate filter: remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Loosen the left and right front wheel housing liner and push to the side. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Loosen the hose clamp -1- and remove the air duct hose.

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-- Loosen the hose clamp -arrow- and remove the air duct hose.

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-- Place the Shop Crane - Drip Tray :VAS6208  underneath.

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-- Loosen the hose clamps -1, 2 and 3-, remove the coolant hoses and let the coolant drain out.

-- Loosen the hose clamps -arrows-, remove the coolant hoses from the coolant pipes on the transmission and let the coolant drain.

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-- Disconnect the fuel supply line -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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

-- Press the release buttons and disconnect the EVAP system hose -2-.

-- Free up the hoses.

-- Loosen the hose clamp -4- and remove the coolant hose.

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-- Remove the bolt -2- and nut -3- and move the right coolant pipe to the side (example illustration above).

-- Disconnect the connector -1- for the Engine Coolant Level Warning Switch -F66-.

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-- Release the retainers with a screwdriver in direction of -arrow- and move the coolant expansion tank to the side (example illustration above).

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

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-- Loosen the hose clamps -arrows- and remove the coolant hoses.

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-- Remove the bolt -2-.

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-- Press the coolant pipes -1- on the fan shroud slightly toward the rear.

-- Remove the refrigerant lines from the A/C compressor. Refer to REFRIGERANT LINES, REMOVING AND INSTALLING TO A/C COMPRESSOR .

Vehicle without Particulate Filter:

-- Remove the connectors from bracket and disconnect:

1. For the Oxygen Sensor 1 after Catalytic Converter -GX7-
2. For the Oxygen Sensor 1 before Catalytic Converter -GX10-

-- Free up the wires to the heated oxygen sensors.

Continuation for All Vehicles:

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

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-- Disconnect the connector -2- from the Engine/Motor Control Module -J623-.

-- Disconnect the connectors -3 and 4- from the bracket.

-- If installed, remove the connector -1- from the bracket and disconnect it.

-- Remove the nut -5- and free up the ground wire.

-- Free up the wires.

-- Release the retainer in direction of -arrow A- and open the cap at the Fuse Panel 4 -ST4- -1- in direction of -arrow B-.

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-- Remove the B+ wire and free it up.

-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

-- Disconnect the starter connector -arrow-.

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-- Loosen the bolts -arrows- for the transmission mount -1- approximately two turns.

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-- Remove the left and right drive axles from the transmission and tie them up toward the rear. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the Adapter :T03000/3  from the Engine Holder Bracket :T03000A  .

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-- Mount the Engine Holder Bracket :T03000A  on the cylinder block with the remaining pins -1- and install the bolts -2 and 3- by hand all the way.

-- Install the Adapter :T03000/3  on the cylinder block and tighten to 20 Nm.

-- Tighten the bolts -2 and 3- to 25 Nm.

-- Install the Engine and Gearbox Jack :VAS6931  on the Engine Support :T03000A  and slightly lift the engine/transmission assembly.

TIP:

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Use a step ladder to remove the assembly mount bolts.

-- Remove the bolts -arrows- and engine mount -1-.

TIP:

The rear bolt in the cylinder block is accessible from the wheel housing side. To do so, loosen the wheel housing liner area and push it aside. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Remove the bolts -arrows- for the transmission mount -1-.

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-- Move the transmission side of the engine/transmission assembly forward and then lower it.