Engine, removing

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.
Drained coolant must be stored in a clean container for disposal or reuse.
During installation, all cable ties must be re-installed at the same location.

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Special tools, testers and auxiliary items required

Pry lever 80 - 200
Old oil collecting and extracting device V.A.G 1782
Hose clamp pliers V.A.G 1921
Spring-type clip pliers VAS 5024 A

Step ladder VAS 5085
Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/12

Special tools, testers and auxiliary items required

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Ring screw 3368

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Drip tray for workshop crane VAS 6208

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Tension strap T10038

Work procedure

CAUTION: There is a risk of injury because the fuel is under very high pressure.

Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.

Reduce fuel pressure in high pressure area → Procedure before opening fuel injection system high pressure area .
Discharge refrigerant circuit Refrigerant R134a - Servicing.
Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

CAUTION: Risk of destroying electrical components when battery is disconnected.

Observe measures when disconnecting battery.

NOTE:

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.

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Remove cover of right luggage compartment side trim - arrows -.

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Remove cover - 1 - above battery.

NOTE:

Ignore - 2 -.

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

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Pull rear engine cover off - arrows -.

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Pull front engine cover off - arrows -.

CAUTION: Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
To reduce pressure, cover coolant reservoir cap with cloth and carefully open.

Open cap on coolant expansion tank.
Remove both front wheels.
Remove front part of left front wheel housing liner → 66 - EXTERIOR EQUIPMENT .
Remove front and rear part of right front wheel housing liner → 66 - EXTERIOR EQUIPMENT .

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Remove sound insulation by loosening fasteners - 1, 2, 4 -.

NOTE:

Ignore - 3 -.

Place drip tray for workshop crane VAS 6208 under engine.

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Remove drain plug - 1 - on Map Controlled Engine Cooling Thermostat F265 and allow coolant to drain.

NOTE:

Ignore - 2 -.

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Remove drain plug - arrow - at front coolant pipe and drain coolant.

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Remove coolant hoses - 1 and 2 - and drain coolant.

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Disconnect vacuum line - arrow -.

CAUTION: Risk of damaging coolant lines and hoses.

Do not stretch, kink or bend coolant lines and hoses.

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Remove bolts - 1 and 2 -.
Disconnect refrigerant lines from A/C compressor.

NOTE:

To prevent dirt and moisture from entering, seal off open lines and connections with clean plugs or protective caps.

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Remove bolts - arrows -.
Remove coolant pipe to ATF cooler from coolant hoses - 2, 3, 4 -.

NOTE:

Ignore - 1 -.

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Free up secondary air injection (AIR) air guide hose - 1 - on ATF cooler bracket.
Remove bolts - arrows -.
Remove ATF cooler and secure it on engine carrier.

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Place drip tray for workshop crane VAS 6208 under engine.
Disconnect right coolant hose - arrow - and drain coolant.

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Free up fuel line and line to EVAP canister on air guide pipe.
Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
Remove vacuum line - 4 - to air guide hose from suction jet pump.

CAUTION: Risk of violating emissions legislation.

Do not open hose connection - 3 - !

Lay aside air guide hose with connected crankcase ventilation hose - 3 - by loosening hose clamps - 2 and 5 -.

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Disconnect secondary air injection (AIR) air guide hose - 1 -.
Remove coolant hose - 2 - by pulling clip out slightly.

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Remove nuts - arrows - and remove right electrical connectors bracket from bulkhead.

NOTE:

Ignore items - 1 to 4 -.

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Disconnect vacuum hose - 1 -.
Remove coolant hose - 2 - from right coolant pipe.
Remove torque support bolt - 3 -.

CAUTION: Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

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Disconnect fuel supply line - arrow - on distribution piece.

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Disconnect electrical connector - 2 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 1 -.
Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.
Remove coolant hose - arrow - and lay it aside.

NOTE:

To collect escaping hydraulic oil, lay a cloth under separating point.

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Disconnect power steering hydraulic pressure line - 1 -.
Remove coolant hose - 2 - from left lower coolant line.

NOTE:

To collect escaping hydraulic oil, lay a cloth under separating point.

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Remove hydraulic hose - arrow - from bottom of hydraulic oil reservoir.

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Remove rubber seal - 1 - and remove plenum chamber covers - 2 and 3 -.

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Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
Loosen wiper arms by tilting slightly from windshield wiper axle.
Remove nuts completely and remove wiper arms.

NOTE:

If wiper arms cannot be removed in this way, use a standard puller.

Remove dust and pollen filter by opening 4 quick-release fasteners.

NOTE:

Cover air duct at air conditioning housing with a clean rag so that nothing can fall in.

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Remove bolts - arrows - at left and right for cowl grill - 1 -.
Carefully pull cowl grill off from retainers at windshield.

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Remove strut tower brace - arrow -.

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Remove cover over engine control module (ECM) - arrows -.

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Remove bolts - arrows -.
Remove retaining bracket and ECM from E-box plenum chamber.

NOTE:

Electrical harnesses remains connected.

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Remove Air Quality Sensor G238 by rotating approx. 90° counter-clockwise - arrow - and removing from bracket.
Release retaining clips - 1 to 4 -.
Fold cover for E-box in plenum chamber, open slightly and pull off toward front.

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Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
Disengage wiring harness at E-Box and bulkhead.
Lay wiring harness aside on engine with engine control module (ECM) connected.
Secure ECM against falling down.

Remove lower right A-pillar trim → 70 - INTERIOR TRIM .
Fold floor covering back.
Remove protective cover from above main fuse holder.

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Fold cap - 2 - aside.
Remove nut - 4 -.
Remove terminal 30 wire to starter.

NOTE:

Ignore items - 1 and 3 -.

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Remove harness clamp - 1 -.

NOTE:

Ignore - 2 -.

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Separate electrical connector - 2 -.
Remove Ground (GND) wire - 1 - from longmember.
Remove wiring harness bracket from longmember - arrows -.
Free up wiring harness.

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Disconnect electrical harness connector - 2 - at Level Control System Sensor.
Disconnect connecting link - 1 - from control arm.
Repeat work procedure on opposite side of vehicle.

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Have a second technician press brake pedal.

CAUTION: Risk of damaging wheel bearing.

To loosen drive shaft collar bolt, vehicle must not be resting on wheels.

Remove collar bolt - 2 - at left and right drive axles - 1 -.

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Remove bolts - arrows - uniformly at left and right.
Remove stabilizer.

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Insert left and right Lifting Eyebolt 3368 from below into hole in strut tower.
Secure Lifting Eyebolt 3368 with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).

CAUTION: Risk of damaging axle joints on upper control arms.

Support wheel bearing housing.

Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

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Remove air spring damper bolt - arrow - from control arm.

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Remove guide control arm - 1 - and control arm - 2 - from subframe.

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Pivot guide control arm - 1 - and control arm - 2 - outward.

CAUTION: Risk of damaging axle joints on guide control arm and control arm.

Tie guide control arm and control arm up to wheel bearing housing - arrows -.

Remove drive axle from transmission flanged shaft.

CAUTION: Risk of damaging brake line.

Carefully tilt wheel bearing housing toward outside.

Remove drive axle.
Repeat work procedure on opposite side of vehicle.

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Remove front transverse beam - arrows -.

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Remove left front muffler nuts - 1 -.

NOTE:

Ignore items - 2 and 3 -.

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Remove right front muffler nuts - 1 -.

NOTE:

Ignore - 2 -.

CAUTION: Risk of damaging decoupling elements in front exhaust pipe.

Do not bend decoupling elements in front exhaust pipe more than 10°.

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Remove nuts - arrows - on front muffler retaining straps.

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Disconnect exhaust system at clamping sleeves - 1 and 2 - and remove front muffler.

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If present, remove heat shield - A - for driveshaft - arrows -.
Remove bolts that connect driveshaft to transmission.
Slide driveshaft back to rear final drive; constant velocity joints can move axially.

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Tie driveshaft up and to the side against heat shield - arrow -.

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Remove bracket for noise insulation - arrows -.

Prepare scissor lift platform:

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Equip Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 as well as Supplementary Set VAS 6131/11 and VAS 6131/12 as follows:

Platform coordinates	Parts from Support Set VAS 6131/10, Supplementary Set VAS 6131/11 and VAS 6131/12
B3	/10-1	/10-4	/10-5	/10-12
G3	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/12-1
G10	/10-1	/10-2	/10-5	/11-3
C14	/10-1	/10-3	/10-5	/10-12
F14	/10-1	/10-3	/10-5	/10-12

Install attachments on scissor lift table by hand first.
Place scissor lift platform VAS 6131 in horizontal position.

Note bubble level (sight glass) on support platform.

Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

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Position support elements from VAS 6131/10 at front on engine as shown in illustration.
Ensure right threaded spindle at front of engine is completely installed.

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Position support elements from VAS 6131/12 at left on transmission as shown in illustration.

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Position support elements from VAS 6131/11 at right on transmission as shown in illustration.

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Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
Twist all spindles of support elements upward far enough until all support pins make contact at support points.
Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

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Remove bolts - arrows - at tunnel cross member.

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Mark installation position of subframe on longmember using a felt tip pen.
Remove bolts - 1 and 4 -.
Remove bolts - 2 and 3 - in diagonal sequence and in stages.

CAUTION: Risk of damaging hose and wiring connections as well as engine compartment.

Check whether all are loosened between engine, transmission, subframe and body.
Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.

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First lower engine/transmission assembly using scissor lift platform VAS 6131 only approx. by dimension - a -.

Dimension - a - = 120 mm maximum.

Identify installation position of selector lever cable bracket with a felt-tip pen for re-installation.

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Press ball socket - 1 - of selector lever cable from selector shaft lever using pry lever 80 - 200.
Remove bolts - 2 and 3 - and remove selector lever cable from transmission.
Lower engine/transmission subassembly downward.
Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.