Engine, Removing

Removing Engine

Special tools and equipment
- Pin wench -VAS3212-
- Mandrel -VAS3204-
- Hose clamps, up to 25 mm diameter -VAS3094-
- Drip tray -VAG1306-
- Open ring spanner -VAS3035-
- Engine support bracket -VAG10-222A-
- Support -VAG10-222A/1-
- Adapter -10-222A/3-
- Lifting appliance -VAS2024A-
- Engine and gearbox support -VW 540-
- Supplementary kit -VW 540/1B-
- Plug spanner -VAS3122B-

Notes:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations.
- Remove engine without transmission toward the front.
- Drained coolant must be stored in a clean container for disposal or reuse.
- Always replace seals and gaskets.
- Do not open coolant circulation system.

Removing
- First determine whether a coded radio is installed. If so, determine the correct coding.
- Switch ignition off and disconnect battery ground strap.






- Remove bolts (arrows) and remove engine covers -A- and -B-.
- Remove cover above air filter.
- Remove plenum cover.






- Remove sound-proofing material (arrows).
- Remove bracket for sound-proofing at unit support.
- Drain engine coolant. Service and Repair
- Remove front bumper Service and Repair
- Remove lock carrier Removal and Replacement






- Remove viscous fan counter-hold using pin wrench -VAS3212-.

Note: The viscous fan has a left-handed thread.

- Mark direction of rotation of ribbed belt






- To loosen ribbed belt, turn clockwise using 17 mm box wrench until two holes are aligned (arrow). Counter-hold in position using mandrel -VAS3204-

Note: Mark direction of rotation of ribbed belt. Reversing the direction in which it runs can ruin it.

- Remove ribbed belt.





- Cut coolant hoses -1- and -2
- Remove coolant reservoir (arrows).
- Disconnect connector for coolant level display.
- Remove valve cover (cylinder bank 4-6).






- Remove hose -1- to vacuum reservoir.






- Remove air distributor (arrows).

WARNING: Fuel system is under pressure! Before opening the system place a rag around the connection. Then release pressure by carefully loosening the connection.






- Disconnect fuel supply and return lines -1 and -2- and move aside.
- Remove hose from Evaporative Emission (EVAP) canister purge regulator valve -3-.






- Disconnect connector -1- at Mass Air Flow (MAF) sensor.
- Disconnect connectors -2- from power output stage and move cables aside.
- Remove air filter.






- Disconnect connector -1- for oxygen sensor at bulk head.
- Disconnect connector -2- for knock sensor.
- Disconnect harness connector -3-.
- Move cables clear.






- Remove pressure hoses (arrows) from charge air cooler to left and right pressure lines.
- Disconnect cable at B+ on battery.
- Disconnect B+ battery cable.






- Move cables to starter aside together with cable channels (arrows).






- Disconnect hose from power steering reservoir to power steering pump with special tool 3094.
- Disconnect power steering hose (arrow)






- Disconnect hydraulic line (arrow).
- Disconnect harness connector from vehicle speed sensor.
- Disconnect harness connector from reverse gear switch.






- Remove wiper arms (arrows).
- Disconnect retaining clip -1- at water deflector.
- Pull off left and right retaining clips -3 on water deflector.
- Remove water deflector.
- Remove cover -2- from E-box (electronics box).
- Open E-box in plenum.
- Unclip ECM retaining bracket.






- Remove ECM, disconnect harness connectors -2- and -3- and remove.
- Disconnect harness connectors -1-.






- Remove hose -1- to power brake booster at bulk head.
- Disconnect ground (GND) -3-.
- Disconnect connectors -2- and -5- at bulk head and remove lower part of connectors from bracket.
- Pull connector -4- out of bracket and move wiring clear.
- Remove bracket for harness connector.
- Remove both coolant hoses to heat exchanger at engine by un-clipping retaining clips on flange.






- Remove hoses-arrows- between turbocharger to left and right charge air coolers.






- Move aside cable -1- to starter by cutting cable tie and un-clipping bracket (arrow).
- Remove hose -2- for cooling generator.






- Disconnect ground (GND) (arrow) from engine support.






- Remove hose clamp (arrow).
- Remove intake manifold -1-.
- Remove coolant line -2-.






- Remove torque support -1-.
- Remove hose clamps (arrows).
- Remove coolant line -2-.
- Place VAG1306 Drip Tray beneath engine.
- Remove oil filter






- Remove hose clamps (arrows).
- Remove oil cooler -1-.






- Remove heat sensor -1- from right turbocharger using 3035.
- Remove heat shields -2- from left and right turbochargers.
- Remove upper bolts -3- to front line to left and right turbochargers.






- Remove heat shield (arrows) above left and right drive axle to transmission.






- Remove hose clamp -1- from left and right heat shield for turbocharger.
- Unbolt left and right exhaust pipes -2 from turbocharger.






- Unbolt coolant lines to oil pan -arrow-.






- Disconnect transmission fluid lines -1-
- Disconnect oil line at turbocharger -2-.

CAUTION: Do not open file refrigerant circuit of the AC system.






- Remove A/C compressor-1...2-.
- Attach A/C compressor (with refrigerant hoses attached) to vehicle using wire.

Notes:
When installing pay attention to guide bushings.
When installing first insert bolt -1- in A/C compressor.
Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.






- Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.
- Remove nuts -1- on left and right engine mounts.

Note: When installing, make sure that locating sleeves -2- engage again.

Vehicles with automatic transmission:

- Remove right charge air cooler by disconnecting upper hose connection; charge air cooler supported in 3x rubber bearings.






- Disconnect air guide at generator support -3
- Unbolt cable at terminal 30/B+ -1-. Tightening torque: 16 Nm
- Unbolt cable at terminal D+ -2-. Tightening torque: 4 Nm






- Remove hex socket bolt -1- , retaining nut -2. Tightening torque: 45 Nm
- Remove bolt -3-. Tightening torque: 22 Nm
- Remove generator -4- downward and out.






1. Remove air intake -1-.
2. Securing points for oil and A/C lines
3. Securing point to engine block
4. Remove hose clamp






- Unbolt cable for terminal 30/B+ -1-.
Tightening torque: 16 Nm
- Disconnect connector for terminal 50 -2-.






- Remove right wheel.
- Remove upper bolt -1- through right wheel housing. Tightening torque: 65 Nm
- Unbolt lower bolt from engine side. Tightening torque: 65 Nm
- Remove starter forward and out.






- Using special tool V175 disconnect torque converter from drive plate.

All Models

- Position 10-222A engine support bridge on bolted flanges of fenders.






- Using 10-222 engine sling together with 10-222A1 engine support bridge and 10-222A3 lift engine up.
- Remove flange bolts from below
- Remove engine support
- Remove flange bolts from above.






- Attach 2024A engine sling at rear-right and left-front and secure.

Note: To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.

WARNING: Install mounting hooks and pins on the engine sling and secure them with the positioning lock.

- Remove front left wheel.
- Support transmission using floor jack.
- Push engine crane into position and attach to engine sling.

Note: Verify that all hoses and lines between engine and transmission have been disconnected.

- Carefully pull engine out toward front until free.
- Guide engine forward out of engine compartment.
- Remove spacer between engine and transmission.