Engine, Removing

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

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS6931
Engine/Gearbox Jack - Engine Support: T10359A
Engine/Gearbox Jack - Pin: T10359/2
Adapter: T10359/3
Securing element from the Transmission Support: 3282
Pry Lever: 80-200
Shop Crane - Drip Tray: VAS6208
Protective Eyewear
Safety Gloves
Step Ladder

NOTE:

The engine with transmission is removed downward. For this reason it is necessary to remove the subframe.

Procedure

Fig 1: Identifying Coolant Reservoir Cap

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CAUTION:

The cooling system is under pressure when the engine is warm. There is a risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

- Wear safety gloves.

- Wear protective eyewear.

- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the coolant expansion tank cap -arrow-.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the front section for the left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Place the : VAS6208 underneath.

-- Disconnect the connector -1-.

-- Lift the clamp -3- and remove the lower right coolant hose from the radiator.

Fig 2: Component Location Engine Coolant Temperature Sensor

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-- Allow the coolant to drain.

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

-- Remove the bolts -1 and 3-.

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-- Release the catch in direction of -arrow- and remove the cover -2-.

-- Free up the coolant hose -2-.

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-- Open the catches in direction of -arrows- and remove the upper air duct -1-.

-- Disconnect the vacuum hose -1-.

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

-- Remove the air filter housing -3-.

-- Remove the bolt -arrow- on the left and right.

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-- Unclip and remove the lower section -1- of the air duct.

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

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-- Disconnect the vacuum hose -2-.

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-- Press the release button on the vacuum hose -1- and remove the hose from the vacuum pump.

Vehicles without Parking Heater:

Fig 3: Identifying Heater Core Hoses

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

-- Hold the coolant hoses downward and allow the coolant to drain.

Vehicles with Parking Heater:

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-- Loosen the hose clamp -1-, lift the clamps -arrows- and remove the coolant hoses.

Continuation for All Vehicles:

Fig 4: Exploded View Of Heated Oxygen Sensor

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-- Disconnect the connectors -1 and 2- and remove them from the bracket. Free up the wires.

-- Remove the bolt -2- and the screw-type clamp.

Fig 5: Catalytic Converter - Tightening Sequence

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-- Remove the nuts -1 and 3-.

NOTE:

The installation position is shown in the illustration with the engine removed for clarity.

Ignore -4-.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

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

-- Disconnect the hose couplings -1 and 2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING . Loosen the hose clamp from the expansion tank -3-.

Fig 6: Identifying Expansion Tank

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-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

Fig 7: Identifying Clamp And Upper Left Coolant Hose

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NOTE:

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

Fig 8: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -1- from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

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-- Remove the connectors -2 and 3- from the bracket and disconnect.

-- Free up the wires.

-- Release the retainers in direction of -arrows- and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver in direction of -arrow-, remove the cover -1- for the engine compartment E-box upward.

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-- Remove the nut -arrow-, disconnect and free up the wires.

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Vehicles with Manual Transmission:

Fig 9: Identifying Connector

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-- Disconnect the connector -2-.

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

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

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- Disconnect the left front connectors from the transmission:

Fig 10: Identifying Park/Neutral Position Switch

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For the Transmission Neutral Position Sensor -G701-
For the Back-Up Lamp Switch -F4-

-- Remove the shift and selector cable from the transmission, remove the cable bracket and move it to the side with the cables. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING (02Q) or SHIFT MECHANISM, REMOVING AND INSTALLING (0GC) .

-- Clamp the hose/line assembly -A- to the slave cylinder with the : 3094 .

Fig 11: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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-- Pull hose/line assembly clip -arrow- out as far as stop.

-- Remove pipe/hose line assembly from the slave cylinder ventilator.

Vehicles with Dual-Clutch Transmission:

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-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING (02Q) or SHIFT MECHANISM, REMOVING AND INSTALLING (0GC) .

-- Disconnect the connector -2-.

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

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

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- To discharge static electricity, touch a ground by hand (without gloves).

-- Do not touch connector terminals in the transmission connector with hands.

-- Disconnect the connector -4- for the Dual-Clutch Transmission Mechatronic -J743-. To do so, turn the twist lock counter-clockwise.

Continuation for All:

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

Fig 12: Identifying Bolts

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-- Loosen the bolts -arrows- for the engine mount approximately two turns.

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

-- Open the clamp -1 and 2- and remove the air duct hose.

Fig 13: Identifying Clamps

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

-- Remove the air duct pipe. Refer to AIR DUCT PIPE FROM CHARGE AIR COOLER TO INTAKE MANIFOLD, REMOVING AND INSTALLING .

Fig 14: Disconnect Charge Air Pressure Sensor Connector

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Vehicles with Parking Heater:

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-- Loosen the clamp -1-, remove the bolt -2- and remove the parking heater muffler.

Continuation for All Vehicles:

Fig 15: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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-- Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation.

-- Pivot the tensioner clockwise in direction of -arrow- to release the tension on the ribbed belt.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioner. If necessary, remove the : T10060A .

CAUTION:

Danger of frostbite from refrigerant.

- Do not open the A/C system refrigerant circuit.

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

Fig 16: Identifying A/C Compressor Components

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-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side. While doing so, do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the left and right drive axles from the flange shafts. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the drive axles to the rear.

NOTE:

Be careful not to damage the protective coating on the drive axle.

-- Loosen the clamping sleeve -arrow- and push it toward the rear.

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-- Remove the catalytic converter with the front exhaust pipe.

-- Remove bolt -arrow- and push the bracket for the wiring harness to the side.

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-- Fasten the : T10359/3 on the : T10359A as shown.

Fig 17: Identifying Engine/Gearbox Jack Engine Support

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-- Tighten the : T10359/2 onto the engine bracket with the securing element -A- from the : 3282 .

-- Place the : T10359 in the : VAS6931 .

-- Position the : T10359A on the cylinder block. Fasten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 18: Identifying Engine Support

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-- Secure the engine with the support element -B- and lift the engine with the transmission.

-- Completely remove the engine mount bolts -arrows-.

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

Fig 19: Identifying Bolts

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-- Carefully lower the engine/transmission assembly in the direction of -arrow 1-.

Fig 20: Identifying Engine Jack

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-- Carefully guide the engine/transmission assembly forward and out to the left in the direction of -arrow 2-.