Engine, Removing: Procedure

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

NOTE:

The engine is removed downward together with the transmission.

Secure the rear lid so that it cannot close because the battery is going to be disconnected.

Access to the luggage compartment when the power is off possible but with difficulty.

CAUTION:

Extremely dangerous due to high-voltage.

Electrocution can cause death or very serious personal injury.

- Have the high-voltage system de-energized by a qualified person.

Disable the high-voltage system. Refer to HIGH VOLTAGE SYSTEM, DE-ENERGIZING .

-- Open the coolant reservoir cap -arrow-.

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CAUTION:

The cooling system is under pressure when the engine is warm. 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 engine cover. Refer to ENGINE COVER .

-- Loosen the outer left and right drive axle bolts. Refer to DRIVE AXLE .

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

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

-- Remove the right front wheel housing liner. Refer to WHEEL HOUSING LINER .

-- Disconnect the connector -2- on the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.

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Drained coolant must be stored in a clean container for disposal or reuse.

-- Place the :VAS6208 underneath.

-- Lift the clamp -1-, remove the lower left coolant hose from the radiator and drain the coolant.

-- Lift the clamp -arrow-, remove the lower right coolant hose -2- from the charge air cooling circuit cooler -1- and drain the coolant.

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-- Loosen the hose clamps -1- and remove the air guide hose.

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-- Remove the bolts -2- on the lock carrier and remove the air guide.

-- Unclip and remove the cover -1- upward from the retainers -arrows-.

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Vehicles With Secondary Air System

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-- Squeeze the locking ring -arrows- on both sides and remove the air lines -1 and 2- from the damper -3-.

-- Remove the damper -1- upward from the rubber bushings -arrows-.

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Continuation For All Vehicles

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

-- Disconnect the 12V battery. Refer to BATTERY .

-- Remove the Electric Drive Power and Control Electronics -JX1-. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .

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-- Remove the Electric Drive Power and Control Electronics -JX1- bracket. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .

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-- Remove the vacuum hose -1- from the brake booster -2-.

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

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-- Remove the front exhaust pipe. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

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-- Disconnect the battery. Refer to BATTERY .

-- Unlock and remove the fuel supply line -1-. Disconnect the couplings. Refer to CONNECTOR COUPLINGS .

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-- Release and remove the breather line -2-. Disconnect the couplings. Refer to CONNECTOR COUPLINGS .

-- Disconnect the connector -3- from the coolant reservoir sensor.

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-- Remove the bolt -2- and move the windshield washer fluid reservoir filler tube forward -1-.

-- Remove the bolts -5- and place the coolant expansion tank -4- on top of the engine with the hoses connected.

-- Lift the clamp -arrow- and remove the upper right coolant hose from the charge air cooling circuit cooler.

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-- Remove the air duct hose -2-.

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-- Pull the air filter housing -1- upward off of the ball pins.

-- Loosen the hose clamp -3- and remove the air duct pipe.

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

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-- Unclip the connectors -1- from the brackets and open the cable guide -arrows- -2-.

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-- Release and disconnect the connectors -1-.

-- Disconnect the ground connection -3- and free up all wiring harnesses.

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

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-- Unlock and disconnect the engine wiring harness connector from the 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 transmission and the body.

-- Free up the wire.

-- Remove the selector lever cable and the lock washer from the ball head.

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-- Remove the cable from the transmission cable bracket very carefully.

NOTE:

Never touch the connector terminals in the transmission connector. The control module as well as the Mechatronic will get damaged by the static discharge.

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

-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743- by pulling the locking mechanism upward in direction of -arrow-.

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-- Disconnect the 12V battery. Refer to BATTERY .

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

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-- Remove the clip from the connection box shield.

-- Remove the three bolts -arrows- and remove the connection box protective plate for the Electric Drive Motor -V141- -1-.

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-- Open the release -arrow- and disconnect the connector -1- from the contact switch on the connection box -2- for the Electric Drive Motor -V141-.

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-- Move the wires to the side.

-- Remove the Electrical A/C Compressor -V470-. Refer to A/C COMPRESSOR .

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NOTE:

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

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

-- Remove the bolts -5- and the bracket.

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-- Remove the bolt -3- about two turns. The bolt is accessible through the right wheel housing.

-- Remove the bolts -2 and 4- about two turns.

-- Remove the bolts -3- from the transmission bracket -1- about two turns.

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-- Disconnect the connector -1- on the Oil Level Thermal Sensor -G266-.

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-- Remove subframe with steering gear. Refer to SUBFRAME .

-- Loosen the bolts -1- and remove the heat shield from the right drive axle.

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

-- Mount the T10497/2 on the housing rib of the cylinder block as shown.

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-- Position the T10497 on the cylinder block using the pin T10497/1 and then tighten the bolt -arrow- to 20 Nm.

-- Attach the :T10497/3 to the :T10497 and tighten the bolt -1- to 20 Nm.

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:VAS6131B , Preparing for Following Procedure

-- Position the :VAS6131/16-1 on the attachment points D7, E7, D8 and E8, and only tighten the bolts -1- hand-tight.

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-- Position the :VAS6131/16-2 on the attachment points D10, E10, D11 and E11, and only tighten the bolts -2- hand-tight.

-- Insert the :3282 -2- into the :VAS6131/16-2 .

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-- Place the :3282/66 on the :3282 and align it.

-- Position the :VAS6131B under the vehicle and raise it.

-- Insert the T10497 -1- into the :VAS6131/16-1 and slightly lift the engine/transmission assembly.

-- Tighten the bolts -3 and 4- to 20 Nm.

NOTE:

Use a commercially available step ladder to remove the subframe mount bolts.

-- Remove the bolts -2 and 3-.

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-- Remove the engine mount bolts -4- completely and then remove the engine mount -1-.

-- Remove the bolts -3- completely from the transmission bracket -1-.

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NOTE:

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, the subframe and the body are loosened.

Carefully guide the engine/transmission assembly with the subframe out of engine compartment when lowering.

-- Slightly lower the engine/transmission assembly.

-- Move the engine/transmission assembly using the :VAS6131B and then lower it farther.