Engine, Removing: Procedure

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

NOTE:

The engine is removed downward together with the transmission.

During installation, all cable ties must be installed at the same location.

When installing, secure all heat shield boots back in the same positions.

WARNING:

There is a risk of scalding due to hot steam and hot coolant.

The cooling system is under pressure when the engine is warm.
Cover the coolant expansion tank cap with a cloth and carefully open it to reduce the pressure.

-- Remove the coolant expansion tank cap -1- in direction of -arrow-.

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

-- Remove the air filter. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery. Refer to BATTERY .

-- Remove the battery tray. Refer to BATTERY .

-- Remove the engine control module. Refer to ENGINE CONTROL MODULE .

-- Remove the turbocharger connection. Refer to TURBOCHARGER CONNECTIONS, REMOVING AND INSTALLING .

-- Release the retainer in direction of -arrow- and remove the vacuum hose -1-.

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NOTE:

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

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-- Free up and disconnect the wires on the connectors. Refer to the figure below;

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-- Free up the wiring harness from the cylinder head cover.

-- Release the connector for the Exhaust Gas Temperature Sensor 3 -G495- and remove. Refer to the figure above;

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-- Unlock and disconnect the connector -2- from the Wastegate Bypass Regulator Valve -N75- -1-.

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-- Remove the nuts -arrows-.

-- Set the Wastegate Bypass Regulator Valve -N75- -1- with vacuum lines on the engine.

-- Remove the NOx Sensor Control Module -GX30- control module and place on the engine with the lines. Refer to NOx Sensor Control Module -GX30-, REMOVING AND INSTALLING .

-- Release the connector from the Reducing Agent Injector -N474- from the plenum chamber bulkhead and remove.

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-- Free up the wiring harness.

-- Remove the metering line -2-.

-- To remove, push the wire connection clip -1- together as shown in the direction of -arrow 1-.

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-- Remove the delivery line in the direction of -arrow 2- without special equipment and without >>sharply<< pulling on it.

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

-- Remove the E-box cover inside the engine compartment -arrows-.

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-- Release and disconnect the connectors -1-.

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-- Unclip the connector -1- and the locking mechanism -arrows- and open the wiring guide -2-.

-- Remove the ground connection -3- and free up the wiring harness.

-- Unclip all wires from the cable guide.

-- Disconnect the connector -right arrow-.

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-- Remove the wiring harness from the bracket -1-.

-- Disconnect and remove the engine wiring connector from the engine control module. Refer to ENGINE CONTROL MODULE .

-- Loosen the nuts -arrows- to disconnect the battery positive cables -1- from the E-box -2-.

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-- Disconnect all other connectors between the starter, transmission and body.

-- Free up the wires.

-- Disconnect and remove the connector for the coolant expansion tank -2-.

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-- Unclip the wiring harness from the coolant expansion tank.

-- Remove the bolts -3- and the coolant expansion tank -2-.

-- Unclip the lines -1- and free up.

-- Lay the coolant reservoir -2- on the engine.

-- Remove the fuel filter and place it with the lines connected on the engine. Refer to FUEL FILTER .

-- Open the couplings -A and B- and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS .

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Vehicles With Manual Transmission

-- Remove the selector mechanism from the transmission. Refer to SELECTOR MECHANISM (02E) , SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

-- Remove the hose/line assembly or plastic hose from the clutch slave cylinder. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (0CG) and CLUTCH MECHANISM (02Q, 02QA) and CLUTCH (02E) .

-- Disconnect the connector from the Park/Neutral Position Safety Switch and Back-Up Lamp Switch -E17- -2-.

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-- Release and disconnect the connector -2-.

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-- Free up the wiring harness for both connectors.

-- Remove the selector mechanism from the transmission. Refer to SELECTOR MECHANISM (02E) , SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

Continuation For All Vehicles

-- Remove the front wheels. Refer to WHEEL, CHANGING or WHEELS AND TIRES .

-- Remove the noise insulation. Refer to NOISE INSULATION .

-- Remove the right and left front wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Remove the subframe. Refer to SUBFRAME .

-- Remove the right and left drive axles. Refer to DRIVE AXLE .

-- Remove the right drive axle heat shield. Refer to DRIVE AXLE .

-- Remove the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the fan shroud. Refer to FAN SHROUD WITH RADIATOR FAN, REMOVING AND INSTALLING .

-- Attach the :VAS531003 to the vehicle as shown.

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-- Unclip the wiring harness from the Engine Preheating Element -Z97- on the bumper cover and the bracket. Refer to OVERVIEW - ENGINE PREHEATER .

-- Lay the lines on the transmission.

-- Place the :VAS6208 underneath.

-- Drain the coolant. Refer to DRAIN THE COOLANT .

NOTE:

Place a cloth under the heater core for the heater, to catch escaping coolant.

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-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

-- Remove the radiator. Refer to RADIATOR, REMOVING AND INSTALLING .

-- Loosen the bolts -arrows- on the engine mount -1- approximately two turns.

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Vehicles With Three Transmission Bolted Connections

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

Vehicles With Two Transmission Bolted Connections

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

Vehicles With A/C System

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-- Remove the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

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

CAUTION:

There is a risk of damaging the A/C compressor, the refrigerant lines and hoses.

Do not stretch, bend or kink the refrigerant lines and hoses.

-- Remove the bolts -arrows-.

WARNING:

Refrigerant can cause serious personal injury.

Do not open the A/C system refrigerant circuit.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side.

Continuation For All Vehicles

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-- Disconnect the connector -4-.

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

-- Push the coolant pipe -1- and Charge Air Cooling Pump -V188- -5- to the side.

-- Loosen the fasteners -arrows- and remove the noise insulation -1-.

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-- Fasten the :T10497 on the cylinder block with the :T10497/1 and the bolt -1- to approximately 20 Nm.

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-- Place the :VAG1383A or :VAS6931 on the :T10497 .

-- Slightly lift the engine/transmission assembly.

NOTE:

Use a commercially available step ladder to remove the assembly mounts bolts.

-- Remove the bolts -arrows- for the engine mount -1- completely.

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Vehicles With Three Transmission Bolted Connections

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-- Completely remove the transmission mount bolts -arrows- completely.

Vehicles With Two Transmission Bolted Connections

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-- Remove the transmission mount bolts -2- completely.

CAUTION:

Risk of damaging the vacuum lines or wires as well as the engine compartment.

Make sure all the vacuum lines or wires between the engine, the transmission and the vehicle body are loosened.
Carefully lower and guide the engine/transmission assembly out of the engine compartment.

-- Lower the engine/transmission assembly.