Engine, Removing
Special tools and equipment
- VAG1383A engine/transmission hoist
- VAG1306 drip tray
- VAG1331 torque wrench (5 to 50 Nm)
- VAG1332 torque wrench (40 to 200 Nm)
- VAS5024 assembly tool for spring-type clamps
- 3408 engine support
- VAS5085 conductor
- G 000 100 grease
- Cable ties
Engine, removing
Procedure
- Engine is removed downward with transmission.
- All cable ties opened or cut during engine removal must be reinstalled at the same locations
Note:
- In the continuing work procedure the battery Ground (GND) strap must be disconnected Therefore, determine whether a coded radio is installed. If necessary, determine anti-theft coding first.
- Remove cover at left above the battery.
- Switch ignition off and disconnect Battery Ground (GND) strap.
- Remove engine cover -1-. To do so, remove 3 bolts (arrows).
- Unclip cover for ignition coils with power output stage.
- Disconnect connector (arrows) to ignition coils with power output stage and move wiring harness clear.
- Remove intake hose between Mass Air Flow (MAP) sensor-G70- and throttle valve control module -J338-
- Remove radiator and fan.
- Remove intake hose to combination valve at upper air filter housing (arrow) and at secondary air injection (AIR) pump motor.
- Remove vacuum and vent hoses from engine.
- Remove brace between intake manifold and exhaust manifold heat shield.
Note:
- Mark connectors for Camshaft Position (CMP) sensors (-G40- and -G163-) before disconnecting. Connectors for crankshaft ventilation and intake manifold change-over valve -N156- must also be marked.
- Disconnect the harness connector on the following components:
After-run coolant pump -V51-
Fuel injectors (-N30- to -N33-, -N83-, -N84-)
Engine speed (RPM) sensor -G28-
Knock Sensor (KS) 1 -G61-
Knock Sensor (KS) 2 -G66-
Oil pressure switch -F1-
Secondary Air Injection (AIR) pump motor -V101-
Valve -1- for camshaft adjustment -N205-
Valve -2- for camshaft adjustment -N208-
Camshaft Position (CMP) sensor-G40-
Camshaft Position (CMP) sensor-G163-
Crankcase ventilation valve
Intake manifold change-over valve -N156-
Note:
- For component locations refer to Powertrain Management.
- Disconnect harness connectors for heated oxygen sensors (-G39- and -G108-) at subframe (arrows).
- Remove all remaining electrical wires from engine and set aside.
- Disconnect/unclamp all electrical wires from transmission, generator and starter and set aside.
- Disconnect fuel supply - as well as return line (arrows) (press release button).
- Disconnect all coolant hoses from engine using VAS5024 hose clamp pliers.
- Unhook hydraulic line for power steering at engine bracket (right side).
- Unbolt power steering vane pump with bracket and secure to body using wire; hoses remain connected.
- Remove vehicle speed sensor (arrow) at transmission.
- Remove front exhaust pipe.
- Remove selector lever cable from transmission.
Vehicles with A/C system
- Observe additional notes and repair work Additional Notes & Assembly Steps For Vehicles With A/C System
Continuation for all vehicles
- Remove drive axles.
- Place 3408 engine support on cylinder block and secure using -2- bolts. Tighten to 40 Nm.
Note:
- To install 3408 engine support, unbolt connecting bolt -1- engine/transmission and bolt in engine support in addition to securing bolt -1-.
- Insert engine/transmission jack VAG1383A into 3408 engine support.
- Unbolt pendulum support -1- at subframe and at transmission (arrows).
- Unbolt securing bolt for right subframe mount -1- and bracket with bolt -2-.
- Unbolt securing bolts for left subframe mount (arrows).
- Lower engine and transmission carefully downward.
Note:
- Engine and transmission must be guided carefully when lowered, to avoid damaging body and components.