Engine, Removing
Special tools and workshop equipment required
- Torque Wrench (5-50 Nm) V.A.G 1331
- Torque Wrench (40-200 Nm) V.A.G 1332
- Engine-/Gearbox Jack V.A.G 1383 A
- Spring Type Clip Pliers VAS 5024 A
- Step Ladder VAS 5085
- Engine Holder Bracket T03000
- Tensioning Strap T10038
- Cable Tie
- Foam Mat
Procedure
To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand.
The engine is removed downward together with the transmission.
All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
Seal removed fuel, ventilation and vacuum lines so no dirt enters the system.
Leave the key in the ignition lock to prevent the steering wheel from locking.
If the engine oil must be drained because of work performed on the removed engine, the oil should be drained with the engine installed. If the engine hangs on the engine lateral bracket T03001, the engine is not in it installed position and less engine oil flows out.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
- To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
-- Check the Diagnostic Trouble Code (DTC) memories of all the control modules. Refer to the vehicle diagnostic tester.
-- Remove the engine cover with the air filter. Refer to ENGINE COVER WITH AIR FILTER .
-- Remove the battery. Refer to Removal and Installation .
-- Open the cover -1- for the E-box and remove the wire -2-.
-- Remove the battery tray bolts -arrows- and remove the battery tray from the vehicle.
-- Remove the plenum chamber bulkhead. Refer to Description and Operation .
-- Disconnect the engine wiring harness connectors from the Engine Control Module (ECM). Refer to one of the following:
- Vehicles through 10.08, refer to ENGINE CONTROL MODULE, THROUGH 10.08 .
- Vehicles from 11.08, refer to ENGINE CONTROL MODULE, FROM 11.08 .
-- Release the pass-through for the engine wiring harness -arrow- and pull off upward.
-- Open the locking mechanisms -arrows- for the wire guide on the longitudinal member.
-- Disconnect the harness connector -4-, open the locking mechanism and set the engine wiring harness -3- on the engine.
-- Disconnect the Ground (GND) wire -1- and starter wires -2 and 5-.
Vehicles with a Automatic Transmission:
-- Disconnect the connector -6- from the multifunction switch.
-- Remove the selector lever cable from the transmission. Refer to SELECTOR LEVER CABLE THROUGH 02.2009 .
Vehicles with a Manual Transmission:
-- Remove the shift mechanism from the transmission. Refer to SHIFT MECHANISM .
-- Remove the brace -1-.
-- Remove the slave cylinder bolts -arrows- and cylinder and set it aside, do not open the line.
Do not operate the clutch pedal after the slave cylinder has been removed. The save cylinder may be damaged by doing this.
-- Disconnect the connector for the backup lamp switch from the transmission.
Continuation for all Vehicles:
-- Disconnect the vacuum hose from the brake booster.
-- Disconnect the harness connector for the heated oxygen sensor -G39- on the bulkhead and free up the wiring harness.
-- Open and close the cap on the coolant expansion tank, to relieve the cooling system pressure.
-- Drain the coolant. Refer to DRAINING AND FILLING .
-- Remove the front and rear sections of the right front wheel housing liner. Refer to Removal and Installation .
To facilitate the removal and installation of the engine without having to open the refrigerant circuit:
-- Remove the ribbed belt. Refer to RIBBED BELT .
The refrigerant can cause serious personal injury.
- Do not open the Air Conditioning (A/C) refrigerant circuit.
Risk of damaging refrigerant lines and hoses.
- Do not stretch, kink or bend the refrigerant lines and hoses.
-- Remove the A/C compressor from the accessory bracket. Refer to Removal and Installation .
-- Secure the A/C compressor to the bumper cover using a tensioning strap T10038 and a suitable mat -A-. Slide the tensioning strap T10038 as far as possible toward the bolt -arrow-.
-- Disconnect the connections to the generator and free up the wiring harness.
-- Remove the 4 exhaust manifold to front exhaust pipe nuts -2- and the exhaust system suspended mount bolts -3-.
-- Remove the front exhaust pipe -1- from the exhaust manifold and secure it firmly to the side. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .
The flex joint in the front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.
-- Remove the right and left drive axles from the transmission. Refer to Removal and Installation .
-- Remove the subframe. Refer to Removal and Installation .
The fuel system is under pressure!
- Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
- Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
-- Disconnect the vacuum line -2- (only through MY 09), the ventilation line -1- and the fuel supply line -3-.
Press the circlip in to release the lines -1 and 2-. Press the circlip upward into the housing to release the line -3-.
-- Seal the lines so that the fuel system is not contaminated by dirt, etc.
-- Remove the bolt -2- and place the windshield washer reservoir -1- toward the front.
-- Remove the bolts -6- and disconnect the connector -3-.
-- Remove the bolts -5- and set down coolant expansion tank -4- with the hoses connected onto the engine.
-- Disconnect the coolant hoses from the radiator and heater core (quick acting couplings).
-- Install the engine holder bracket T03000 as follows:
- Remove the pin T03000/1 from the engine holder bracket T03000.
- Install the engine holder bracket T03000 to the cylinder block using the pin -3- and tighten the bolts -1 and 2- hand tight.
- Then, install the pin T03000/1 and tighten it to 20 Nm.
- Then, tighten the bolts -1 and 2- to 25 Nm.
-- Place the engine-/gearbox jack V.A.G 1383 A on the engine holder bracket T03000 and lift the engine/transmission slightly.
Use the step ladder VAS 5085 to remove the bolts from the engine/transmission mounts.
-- Remove the engine mount from above. To do so, remove the bolts -1, 2 and 3-.
The rear bolt -2- is accessible through a hole in the wheel housing.
-- Remove the bolts -arrows- from transmission mount from above.
Verify that all hoses and lines between the engine/transmission and body have been disconnected.
A 2nd technician is needed to lower the engine/transmission.
The engine/transmission must be guided with care to prevent damage while lowering.
-- Carefully lower the engine/transmission. When doing this, rotate or push the engine/transmission, as necessary.