Removing Engine

WARNING: This page is about a different variant/trim than selected.

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
1. → Secure components to prevent them from falling down.

WARNING: Damaged fuel lines

Escaping fuel in the engine compartment
Fire in the engine compartment
1. → Do not loosen hoses using sharp-edged tools.
2. → Replace damaged fuel lines.

WARNING: Caustic fluids

Danger of chemical burns
1. → Wear personal protective gear.
2. → Ensure that there is good ventilation.
3. → Avoid contact with caustic fluid.
4. → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

CAUTION: Hot components

Risk of burns
1. → Let hot components cool down.
2. → Wear personal protective gear.

NOTIFICATION

Aggressive fluids

Risk of damage to components and surfaces
1. → Do not spill fluids.
2. → In the event of contact, wash the component or surface with water.
3. → Replace components that are already damaged.

NOTIFICATION

Opened refrigerant system for repairs.

Moisture penetrated into the refrigerant system.
Risk of contaminating the refrigerant circuit.
Risk of saturation and irreparable damage to desiccator.
Irreparable damage to the desiccator can damage the compressor and evaporator.
1. → The desiccator must be replaced if the air humidity is high and if the refrigerant circuit is left open for a long time.

Information

Open connections and lines must be closed off using suitable stoppers or caps.

Information

The pictures shown in this document may differ from the original.

Remove pressure hose -1- .

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Pressure hose on throttle valve
1. 1.1 Loosen screw-type clamps -2-
2. 1.2 Remove pressure hose -1- with screw-type clamps -2- .
3. 1.3 Release and disconnect electric plug connection -3- .
Disconnect pressure hose -1- .

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Pressure hose on turbocharger
1. 2.1 Loosen screw-type clamp -2- .
2. 2.2 Pull pressure hose -1- off the turbocharger.
Disconnect upper coolant line -2- from the radiator.

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Upper coolant line on radiator
1. 3.1 Lift up retaining clip -1- and pull upper coolant line -2- off the radiator.
  1. 3.1.1 Soak up any emerging coolant using suitable aids.
  2. 3.1.2 Close off connection openings using suitable stoppers.
Disconnect lower coolant line -1- from the radiator.

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Lower coolant line on radiator
1. 4.1 Unclip clip -2- .
2. 4.2 Release and disconnect electric plug connection -3- .
3. 4.3 Lift up retaining clip -4- and pull lower coolant line -1- off the radiator.
  1. 4.3.1 Soak up any emerging coolant using suitable aids.
  2. 4.3.2 Close off connection openings using suitable stoppers.
Detach heat shields from coolant lines.

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Heat shield on coolant line
1. 5.1 Open and remove heat shield -1- .
2. 5.2 Open heat shield -2- and leave it on the coolant line.
Disconnect coolant lines -1 and 2- from the engine.

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Coolant lines on engine
1. 6.1 Lift up retaining clip -3- and pull off coolant line -1- .
  1. 6.1.1 Soak up any emerging coolant using suitable aids.
  2. 6.1.2 Close off connection openings using suitable stoppers.
2. 6.2 Loosen spring band clamp -4- using VAS 6890 - spring band clamp pliers and disconnect coolant line -2- .
  1. 6.2.1 Soak up any emerging coolant using suitable aids.
  2. 6.2.2 Close off connection openings using suitable stoppers.
3. 6.3 Move coolant lines -1 and 2- towards the body and secure with tie-wraps.
WARNING:
Highly inflammable or explosive materials
- Danger of fire or explosion
  1. → Avoid contact with hot parts or sources of ignition.
  2. → Use suction to remove ignitable vapours.
  3. → Attach warning sign in a clearly visible position.
  4. → Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
  5. → Secure collection containers/vessels to prevent them from tipping over.
WARNING:
Hot fuel and hot fuel lines.
- Danger of scalding
  1. → Allow the fuel to cool down before opening line connections.
  2. → Wear protective gloves.
  3. → Wear protective goggles.
Disconnect supply line -1- from the engine.

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Supply line
1. 7.1 Check sealing rings on the plug-in coupling for damage and leaks and replace the supply line if necessary.
2. 7.2 Disengage supply line -1- from bracket -2- .
3. 7.3 Release and disconnect quick connector -3- .
  1. 7.3.1 Close off connection openings using suitable stoppers.
4. 7.4 Move supply line -1- towards the body and secure with tie-wraps.
Disconnect active carbon filter line -1- from the engine.

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Active carbon filter line
1. 8.1 Loosen spring band clamp -2- using VAS 6890 - spring band clamps pliers.
2. 8.2 Pull off active carbon filter line -1- and move it towards the body.
Open clip -1- move coolant hoses -2 and 3- upwards and secure them to the engine with a tie-wrap.

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Coolant hoses for radiator
Expose wiring harness (section: front left of engine compartment) -1- .

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Wiring harness (section: front left of engine compartment)
1. 10.1 Release and disconnect electric plug connections -2- .
2. 10.2 Unclip clips -3- .
3. 10.3 Guide wiring harness -1- up towards the DME control unit.
Disconnect air-conditioning compressor -1- from the engine.

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Air-conditioning compressor
1. 11.1 Unscrew screws -2- .
2. 11.2 Secure air-conditioning compressor -1- to the longitudinal member using tie-wraps for example.
Disconnect vacuum lines -1- from plastic bracket -2- .

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Vacuum lines on plastic bracket
1. 12.1 Unclip clip -3- .
2. 12.2 Release quick connectors -4 and 5- and disconnect vacuum lines.
3. 12.3 Unclip vacuum lines -1- from plastic bracket -2- and remove plastic bracket -2- .
Disconnect vacuum line -1- from the engine.

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Vacuum line on engine
1. 13.1 Unclip vacuum line -1- from brackets -2- .
2. 13.2 Release and disconnect quick connector -3- .
Remove DME control unit holder -1- .

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DME control unit holder
1. 14.1 Disconnect electric plug connection -2- from DME control unit holder.
2. 14.2 Unclip clips -3- .
3. 14.3 Unscrew screw -4- and screw off nut -5- .
4. 14.4 Remove DME control unit holder -1- .
Disconnect engine wire harness -1- next to the dome.

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Engine wire harness next to left dome
1. 15.1 Unclip clip -2- .
Remove fuse box cover -1- .

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Fuse box cover
1. 16.1 Unscrew screws -2- and remove fuse box cover -1- .
Disconnect relay carrier -1- from fuse box.

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Relay carrier
1. 17.1 Release and disconnect electric plug connections -2- .
2. 17.2 Unscrew nut -3- .
3. 17.3 Press locking lugs -4- and remove relay carrier -1- by pulling it upwards.
Remove B+ cover -1- .

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B+ cover
Disconnect B+ lines -1- next to the fuse box.

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B+ lines next to fuse box
1. 19.1 Unscrew nuts -2 and 3- .
2. 19.2 Disconnect B+ lines -1- from the distributor.
Disconnect ground lines -1- next to the fuse box.

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Ground lines next to fuse box
1. 20.1 Unscrew nut -2- .
2. 20.2 Unclip ground lines -1- from bracket -3- .
Disconnect electric line for right engine mount -1- .

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Electric plug connection for right engine mount
1. 21.1 Release and disconnect electric plug connection -2- .
2. 21.2 Unnlin clips -3- .
3. 21.3 Guide electric line for right engine mount -1- towards the plenum panel.
Disconnect electric line for right plenum panel -1- .

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Electric line for right plenum panel
1. 22.1 Unclip clips -2- .
2. 22.2 Release and disconnect electric plug connection -3- .
3. 22.3 Guide electric line for right plenum panel -1- towards the centre plenum panel.
Disconnect electric line -1- from the coolant reservoir.

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Electric line at coolant reservoir
1. 23.1 Release and disconnect electric plug connection -2- .
2. 23.2 Unclip clips -3- .
Disconnect electric wire harness for engine -1- from bracket -2- .

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Electric wire harness for engine
1. 24.1 Unclip clips -3- .
2. 24.2 Guide electric wire harness for engine -1- towards the left plenum panel.
Disconnect electric wire harness for transmission -1- .

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Electric wire harness for transmission
1. 25.1 Release and disconnect electric plug connections -2 and 3- .
2. 25.2 Unclip clips -4- .
3. 25.3 Guide electric wire harness for transmission -1- towards the engine.
Disconnect electric line for steering -1- .

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Electric line for steering
1. 26.1 Release and disconnect electric plug connection -2- .
2. 26.2 Open line bracket -3- .
3. 26.3 Guide electric line for steering -1- towards the transmission.
Disconnect engine wire harness -1- from the body.

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Mounting for engine wire harness on body
1. 27.1 Open line bracket -2- and unclip clips -3- .
2. 27.2 Carefully place all sections of the disconnected engine wire harness -1- including the relay carrier down on the engine.
Open locking lug -1- with a screwdriver, open housing cover -2- on the right longitudinal member and remove it.

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Housing cover
Disconnect electric lines on the right longitudinal member.

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Electric lines on right longitudinal member
1. 29.1 Unclip clip -7- and move headlight vent line -8- aside.
2. 29.2 Unscrew nut -2- and move ground lines -1 and 6- aside.
3. 29.3 Release and disconnect electric plug connection -5- and remove it from the holder.
4. 29.4 Unscrew nut -4- , remove ground line -3- and set it aside.
Press in locking lugs -1- , pull off ground line -2- in -direction of arrow- and guide it down towards the engine.

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Ground line
Loosen tie-wrap -1- .

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Tie-wrap near right wheel housing
Disconnect lines -1 and 2- from engine mount bracket.

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Lines on engine mount bracket
1. 32.1 Loosen tie-wrap -3- .
2. 32.2 Unscrew nut -4- .
3. 32.3 Guide ground line -2- towards the right wheel housing.
Disconnect ATF lines -1- from the engine.

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ATF lines on engine
1. 33.1 Unscrew screw -2- .
Unclip cover -1- .

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Cover on underside of transmission

Information

You will need a second mechanic to help you with this step.
Loosen flywheel -1- from the drive plate.

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Flywheel on drive plate
1. 35.1 Unscrew screw -2- and get another mechanic to counter at the crankshaft pulley at the same time.
2. 35.2 Turn the crankshaft a further 120° in direction of rotation of the engine.
3. 35.3 Unscrew the two remaining screws -2- in the same way.
Information
- Before loosening the screws on the transmission support, the installation position of the transmission support must be marked using a water-resistant felt-tip pen, for example.
- The screws must only be loosened, but not unscrewed!
Loosen screws on transmission support -1 and 3- .

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Transmission support

Information

The ATF line must be disconnected from the transmission in order to loosen the engine/transmission flange screws fully.
Disconnect ATF line -1- on the transmission.

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ATF lines on transmission
1. 37.1 Unscrew screw -2- .
2. 37.2 Disconnect ATF line -1- from the transmission.
3. 37.3 Close off connection openings using suitable stoppers.
Loosen flange screws securing engine to transmission.

Fig 1: Engine Flange Screws Loosening Sequence
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Flange screws securing engine to transmission
1. 38.1 Unscrew screws -1 to 4- and remove bush -5- .
2. 38.2 Unscrew screws -6 to 8- .
3. 38.3 Pull the starter off the transmission and leave it in installation position.
Secure the transmission.

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Tension strap on transmission
1. 39.1 Secure tension strap -1- as shown on the transmission mount and tunnel transverse strut.
Support transmission on the body using 10-222A - support bracket .
1. 40.1 Secure 10-222A/8 - adapter to 10-222A - support bracket with wing screws.
2. 40.2 10-222A - Support bracket with 10-222A/8 - adapter must be positioned on the spring strut domes at the left and right.
3. 40.3 Connect transmission and 10-222A/10 - spindle using 3147 - transmission mount and pre-tension 10-222A/10 - spindle slightly.
4. 40.4 Pre-tension the tension strap.
Use 2024A - lifting tackle to secure the engine to VAS 6100 - workshop crane .
> 1001IN - LIFTING THE ENGINE (WORKSHOP CRANE)
Loosen engine from engine mount brackets -1- .

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Engine mounts on engine mount brackets
1. 42.1 Unscrew screws -2- .
2. 42.2 Raise the engine using VAS 6100 - workshop crane until the engine mounts -1- are free.
3. 42.3 Turn 10-222A/10 - spindle of the 10-222A - support bracket further.
Information

Pay particular attention to the following points when guiding out the engine:
- The engine must have been secured properly to the engine crane.
  > 1001IN - LIFTING THE ENGINE (WORKSHOP CRANE)
- All hose and line connections between the engine, transmission, unit carrier and body must have been disconnected.
- The engine must have adequate clearance.
- Make sure not to damage any add-on parts when guiding out the engine.
Information

You will need a second mechanic to help you with this step.
Disconnect engine from transmission and guide it up out of the engine compartment using VAS 6100 - workshop crane .