Engine, Removing

Special tools and workshop equipment required 

• Pry Lever: 80-200 
• Engine Bung Set: VAS6122 
• Coolant Collection System: VAS5014  or Shop Crane - Drip Tray: VAS6208 
• Hose Clip Pliers: VAS6340 
• Hose Clip Pliers: VAS6362 
• Engine and Gearbox Jack: VAS6931 
• Engine Holder Bracket: T03000A  , or alternatively Engine Holder Bracket: T03000  with Pins: T03000/3  .
• Commercially available Step Ladder
• Safety Gloves
• Protective Eyewear

Tools, Preparing

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-- The : T03000A  is needed for the engine removal. If only the : T03000  is available it must be equipped with two holes.

• Hole -a- = 20 mm diameter.
• Dimension -b- = 45 mm.
• Dimension -c- = 34 mm

-- In addition the Engine Holder Bracket - Pins T03000/3 are required.

Procedure 

• The engine is removed downward together with the transmission.
• During installation, all cable ties must be installed at the same location.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Drain the refrigerant circuit. Refer to REFRIGERANT CIRCUIT, DISCHARGING .

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Vehicle without particulate filter: remove the rear catalytic converter or the exhaust pipes. Refer to REAR CATALYTIC CONVERTER/EXHAUST PIPE, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove the engine cover upward in direction of -arrows-.

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-- Remove the bolts -arrows- and air duct -1-.

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-- Free up the transmission ventilation hose -4-.

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-- Loosen the clamps -1 and 2- and remove the air duct hoses.

-- Remove the air filter housing upward from the retaining pin.

-- Free up the wiring harness on the bracket -1- for the air filter housing.

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-- Remove the bolts -arrows- and remove the bracket for the air filter housing.

-- Vehicle with particulate filter: remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Loosen the left and right front wheel housing liner in the front area and push slightly to the side. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Loosen the hose clamp -1- and remove the air duct hose.

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

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-- Place the container of the : VAS5014  or the : VAS6208  underneath.

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-- Loosen the hose clamps -1, 2 and 3-, remove the coolant hoses and let the coolant drain out.

-- Loosen the hose clamps -arrows-, remove the coolant hoses from the coolant pipes on the transmission and let the coolant drain.

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-- Disconnect the fuel supply line -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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

-- Press the release buttons and disconnect the EVAP system hose -2-.

-- Free up the hoses.

-- Loosen the hose clamp -4- and remove the coolant hose.

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-- Remove the bolt -2- and nut -3- and move the right coolant pipe to the side.

-- Disconnect the connector -1- for the Engine Coolant Level Warning Switch -F66-.

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-- Release the retainers with a screwdriver in direction of -arrow- and move the coolant expansion tank to the side.

-- Loosen the hose clamp -arrow- and remove the coolant hose.

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-- Loosen the hose clamps -arrows- and remove the coolant hoses.

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-- Remove the bolt -2-.

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-- Press the coolant pipes -1- on the fan shroud slightly toward the rear.

-- Remove the refrigerant line from the A/C compressor. Refer to REFRIGERANT LINES, DISCONNECTING AND CONNECTING AT A/C COMPRESSOR .

-- Remove the connectors from bracket and disconnect:

1. For the Oxygen Sensor after Catalytic Converter -G130-
2. For the Heated Oxygen Sensor -G39-

-- Free up electrical wires to oxygen sensors.

-- Disconnect the connector -1-.

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-- Remove the vacuum line -2- from the brake booster at the same time do not damage the vacuum line.

• Use : 80-200  in the following steps to remove the spiral clips.
  Fig 3: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -1- from the Engine Control Module -J623-.

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-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Remove and disconnect the connector -3- for the Dual-Clutch Transmission Mechatronic -J743- from the bracket.

-- Remove the connector -2- from the bracket and disconnect it.

-- Free up the wires.

-- Remove the nut -4- and free up the ground wire.

-- 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- and free up the wire.

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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 .

-- Disconnect the connector -1- by sliding the retainer toward the rear and pressing the release down.

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-- Pry up the cap -2-.

-- Remove the nut -3- and free up the terminal 30/B+ wire.

-- Loosen the bolts -arrows- for the transmission mount -1- approximately two turns.

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-- Remove the left and right drive axles from the transmission and tie them up toward the rear. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the : T03000/3  from the : T03000A  .

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-- Mount the : T03000A  on the cylinder block with the remaining pins -1- and install the bolts -2 and 3- by hand all the way.

-- Install the : T03000/3  on the cylinder block and tighten to 20 Nm.

-- Tighten the bolts -2 and 3- to 25 Nm.

-- Install the : VAS6931  on the : T03000A  and slightly lift the engine/transmission assembly.

TIP:

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Use a step ladder to remove the subframe mount bolts.

-- Remove the bolts -arrows- and engine mount -1-.

TIP:

The rear bolt in the cylinder block is accessible from the wheel housing side. To do so loosen the wheel housing liner and push to the side. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- for the transmission mount -1-.

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-- Move the transmission side of the engine/transmission assembly forward and then lower it.