Recommendations for removing the engine
Before starting work, carefully read the entire section on removing the engine.
If the engine is removed for repair, it is necessary to select a place for work, provide space for maintenance and storage of spare parts. It is recommended that repairs be carried out at a workshop or in a garage with a flat, horizontal floor with a clean hard surface.
Before removing, clean and wash the engine and engine compartment. To remove the engine, use a lifting device that allows you to safely lift the power package.
If you are removing the engine for the first time, you must invite an experienced specialist. Some work should be done with an assistant.
All clips and clamps that are damaged or cut when removing the engine, replace with new ones when assembling the engine.
The engine is removed forward without a gearbox.
Drained coolant must be collected and disposed of.
Before disconnecting the battery, find out if you have a radio activation code.
Withdrawal
The battery is located under the luggage compartment floor.
Turn off the ignition and disconnect the wire «masses» from the battery.
Pic. 3.2–1. Screw location of the left ventilation grille
Turn out the screw of fastening of the left ventilating lattice of a bumper, at the same time the right lattice is also released. Remove the grates (pic. 3.2–1).
Pic. 3.2–2. An arrangement of screws of fastening of the bottom mudguard of a motor compartment
Turn out screws and remove the bottom mudguard of a motor compartment (pic. 3.2–2)
Remove the left and right side of the bumper.
Vehicles with headlight washers
Disconnect the hose passing through the hole in the lower part of the bumper from the washer nozzles.
Remove the front bumper.
Install a coolant drip tray under the engine.
Remove the plug at the bottom of the radiator and drain the coolant.
Loosen the mounting clamps and remove the air intake pipe connecting the air filter and the throttle body.
Pic. 3.2–3. Location of engine cover screws
Loosen the screws and remove the engine cover (pic. 3.2–3).
Loosen the clamp securing the coolant hose to the right toothed belt guard.
Pic. 3.2–4. Arrangement of screws of fastening of a casing of the control unit
Turn out seven screws and remove a casing of the control block located in the left back part of a motor compartment (pic. 3.2–4).
Pic. 3.1–9. Location of the engine control unit (1), drive control unit (2) and electrical connectors (3) on the bulkhead of the engine compartment
Disconnect the electrical connectors from the engine control unit 1 (see fig. 3.1–9) and drive control unit 2, as well as all electrical connectors on the bulkhead of the engine compartment.
Remove the screws securing the cruise control system control unit with relay and fuse box (see fig. 3.1–9).
Remove the seal from the top of the baffle separating engine compartment and ventilation chamber.
Label and disconnect electrical wires from the engine.
Release the two clips securing the flexible wire sheath.
Unscrew the insulating braid of the wires from the bulkhead of the engine compartment, remove the adapter sleeves from the engine compartment, remove the wires from the bulkhead and take them to the side.
Disconnect the hose from the servomotor.
Disconnect the vacuum pipe from the cruise control control unit.
Disconnect the accelerator cable.
Pic. 3.1–16. An arrangement of collars of fastening of hoses of system of cooling to a broad tank (arrows on the right) and to the heater fittings (arrows on the left) on the bulkhead of the engine compartment
Loosen the clamps (arrows on the left, see fig. 3.1–16) and disconnect the coolant hoses going to the heater.
Disconnect the electrical connectors of the lambda sensors on the left and right sides, release the wires of the sensors from the clamps and take the wires to the side.
Unscrew and remove the air filter cover.
Disconnect the electrical connector from the air mass meter.
Disconnect the electrical connector from the ACF valve.
Loosen the clamps and remove the cooling system pipe connecting the expansion tank and radiator.
Remove the supply pipe to the expansion tank after removing the power steering fluid tank.
Disconnect the vacuum pipe to switch the intake manifold in front of the left headlight.
Pic. 3.2–5. Location of electrical connectors and fuel line fastening elements: 1, 5, 6, 10 – fuel line fastening bolts; 2, 4, 7, 9 - clamps; 3, 8 - electrical connectors for knock sensors
Disconnect electrical connectors 3 and 8 (pic. 3.2–5) from the knock sensors on the left and right sides of the fuel line.
Release the four clamps 2, 4, 7 and 9 securing the electrical wires.
Disconnect the electrical connectors from the fuel injectors on the left and right side of the engine.
Turn out bolts 1, 5, 6 and 10 and, being careful, remove a fuel highway.
Close the openings on the engine with a clean rag.
Remove the front left and right exhaust manifold bolts (one bolt).
Pic. 3.2–6. Arrangement of fastening elements of the transverse beam and elements of the exhaust system: 1 - bolted connector; 2, 3 - catalytic converter mounting bolts
Turn out bolts of fastening of a cross beam shown by arrows in fig. 3.2–6.
Turn out bolts of connector 1 of system of release.
Remove the left catalytic converter.
Release the release system clips and remove it.
Unscrew the front exhaust pipes from the exhaust manifolds.
Unscrew the catalytic converter bracket with spring and remove the catalytic converter together with the front exhaust pipe.
Remove the heat shield located under the converter.
Unscrew the selector lever cable heat shield from the transmission oil pan.
Pic. 3.2–7. Location of the mark and bolts of the drive shaft flange to the gearbox
Mark the flanges of the drive shaft and gearbox, remove the bolts and disconnect the drive shaft from the gearbox (see fig. 3.2–7).
Turn out bolts of fastening of a support of a shaft of a drive and establish a support under a shaft.
Unscrew the selector lever cable from the bracket, disconnect it from the gearbox and move it aside.
Remove the cover covering the electrical connections.
Disconnect the starter wire at the junction box and bracket.
Unscrew the nuts securing the wires, disconnect the wires and take them aside.
Disconnect the air duct mount from the generator.
Disconnect the pipe to the transmission oil heat exchanger.
Unscrew the coolant hose at the base of the radiator.
Disconnect the coolant temperature sensor electrical connector located above the hose.
Pic. 3.2–8. The location of the lower arm mounting bolts
Unscrew the lower arm mounting bolt, do not lose the gaskets (pic. 3.2–8).
Pic. 3.2–9. The location of the screws for fastening the radiator air duct and the pressure sensor connector
Loosen the radiator duct screws (pic. 3.2–9).
Disconnect the pressure sensor electrical connector (see fig. 3.2–9).
Disconnect the electrical connectors from the left and right headlights.
Remove the left headlight.
Disconnect the electrical connector from the catalytic converter temperature sensor and move it aside.
Unscrew the heat exchanger and take it away from the radiator.
Disconnect the radiator fan electrical connectors, release the wires from the clamps and take them to the side.
Remove the hood supports in both front fenders.
Remove the bolts located under the hood supports, while retaining the washers located under the bolts.
Unscrew the elastic elements on both sides of the bumper.
Remove the front cross member along with the radiator.
Pic. 3.2–10. Installing tool 3204 to loosen the poly V-belt tension
Loosen the poly V-belt using tool 3204 and remove the belt (pic. 3.2–10).
Warning: Mark the direction of rotation of the V-ribbed belt with chalk, marker or paint. If the V-ribbed belt rotates in the opposite direction during installation, this will lead to its destruction.
Unscrew the poly V-belt pulley on the power steering pump, while retaining the gasket located under the pulley, as it must be used during installation.
Pic. 3.2–11. An arrangement of bolts of fastening of the pump of the amplifier of a steering
Turn out bolts of fastening of the pump of the amplifier of a steering and, without disconnecting pipelines, take it aside (pic. 3.2–11).
Pic. 3.2–12. Arrangement of bolts of fastening of the compressor of the conditioner
Turn out bolts of fastening of the compressor of the conditioner and take away the compressor aside, without disconnecting pipelines from it (pic. 3.2–12).
Retain the A/C compressor guide bushings.
Install the gearbox lifting tool VAG 1383, lift the tool so that the weight of the gearbox is supported by the tool.
Pic. 3.2–13. Arrangement of bolts of fastening of the right and left support of a transmission
Turn out bolts of fastening of the left and right support of a transmission, remove an arm of fastening of a transmission and adaptation VAG 1383 (pic. 3.2–13).
Pic. 3.1–31. The location of the engine mounting bolts to the lower frame
Unscrew the bottom bolts of fastening of the engine to the lower frame shown by arrows in fig. 3.1–31.
Install the hood vertically and secure it in this position.
Screw the holders VAG 3180 to the engine.
Make sure all electrical wires, hoses, fittings and pipes are disconnected from the engine.
Hang a gripper with a lifting capacity of at least 500 kg on the hoist and fasten it to the holders on the engine.
Being careful, lift the engine, move it away from the gearbox and remove it forward from the engine compartment.
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
When installing the engine, it is necessary to replace it with new self-locking nuts and bolts, which were tightened by additional turning to a certain angle, as well as sealing rings and gaskets.
When installing, check for the presence of guide bushings that determine the position of the air conditioning compressor.
If the gearbox was removed from the engine, during installation check the presence of centering bushings, the relative position of the engine and gearbox.
When connecting the engine to the gearbox, be careful not to damage the engine speed sensor.
Vehicles with manual transmission
Clean the splines of the drive shaft and, when reusing the clutch disc, remove traces of corrosion from it. Lubricate the shaft splines with a thin layer of grease G 000 100.
Check the condition of the clutch release bearing and replace it if necessary.
Using a drift, check the centering of the clutch disc.
Check the condition of the needle bearing at the end of the crankshaft on the flywheel side. Replace bearing if necessary.
Vehicles with automatic transmission
To attach the torque converter to the friction lining, bolts of the original design must be used.
Check the correct installation of the torque converter.
Reinstall the engine and rock it from side to side to ensure it is properly supported on its supports.
Pic. 3.2–14. Engine support elements
Install the engine mount, while checking that it is not stressed (pic. 3.2–14).
Install poly V-belt.
Check accelerator cable adjustment.
Fill with coolant. Coolant must not be reused if the cylinder head has been removed or the cylinder block has been replaced.
Fill the power steering system with oil and bleed air from it.
Pour into the engine engine oil.
Make sure that the exhaust system is correctly mounted on the suspensions and does not touch the body when rocking.
Check that the electrical connectors are connected correctly.
Connect wire «masses» to the battery.
Turn on radio and enter the code into it.
Raise the windows with the power windows up to the stop. Then press all power window switches again for at least 1 second to the closed position to activate the power window control unit.
Set the time on the clock.
Before starting the engine, check the presence and level of oil in the engine.
Pic. 3.2–15. The location and numbering of the bolts for fastening the mechanical gearbox to the engine: A - the location of the centering sleeve
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