Engine, Removing
Removing
Note:
^ Replace all cut and faulty cable ties. Refit cable ties in the same position when installing the engine.
^ The engine is removed from the front without the gearbox.
^ Catch drained off coolant in a clean container for re use or disposal.
Vehicles with automatic gearbox:
^ Shift selector lever into position "N".
All models:
^ Observe or obtain radio code on vehicles with coded radio.
^ Remove rubber seal from plenum chamber cover in direction of arrow.
^ Remove plenum chamber cover -1. from the front.
^ Disconnect Ground strap -arrow- at battery with ignition switched off.
WARNING! Hot steam can escape when opening cap on expansion tank. Cover cap with a cloth and open carefully.
^ Carefully open cover of coolant expansion tank.
^ Remove engine cover -arrows-.
^ Remove air filter cover -arrow-.
^ Remove bolts -arrows-.
^ Remove air ducts -1- and -2-.
^ Remove front bumper:
^ Remove sound insulation -arrows-.
^ Unbolt bracket for sound insulation - arrow-.
^ Remove air cowl in front of charge air cooler -arrows-.
^ Unclip temperature sensor for ambient temperature display from bracket.
^ Unbolt power steering hydraulic oil cooling pipe -arrows- and ensure it is free. Do not open hydraulic oil circuit.
^ Place drip tray VAG 1306 below engine.
^ Turn drain screw -arrow- on radiator counter-clockwise. If necessary, install a drain hose on connection.
^ Pull off bottom coolant hose retaining clip -arrow- and remove coolant hose from radiator.
^ Disconnect lower coolant hose on oil cooler -arrow- and drain off remaining coolant.
^ Disconnect coolant hose from connection for thermostat.
^ Remove air duct hose -arrow- to bottom left charge air cooler from lock carrier.
^ Remove air duct hose to bottom right charge air cooler from lock carrier.
Vehicles with automatic gearbox:
Note: Observe cleanliness rules when working on the automatic gearbox:
^ Place drip tray underneath to collect oil.
^ Detach ATF lines -arrows-.
^ Unscrew bracket for ATF lines from left of engine.
All models:
^ Unclip green connector -arrow- for air conditioner magnetic clutch on lock carrier (bottom right). Separate connector and secure wiring aside.
^ Disconnect electrical connector -arrow- for headlights on both sides of vehicle.
^ Disconnect electrical connector -arrow- for turn signals on both sides of vehicle.
^ Disconnect electrical connectors -1- from both signal horns and secure wiring aside.
^ Disconnect hood lock cable from lock carrier:
^ Remove cover of power steering reservoir and disconnect connectors 1 to 5.
^ Secure wiring harness aside.
^ Disconnect coolant hose from top of radiator -arrow-.
WARNING! The air conditioner refrigerant circuit must not be opened.
Note: To prevent damage to the condenser and refrigerant lines1hoses, ensure that the lines and hoses are not stretched, kinked or bent.
^ Remove air cowls from radiator -4 (left and right).
^ Remove securing bolts -1- and -2- for condenser.
^ Disconnect connector -3- from air conditioner pressure switch -F129-.
^ Pull condenser up out of its bracket, pivot towards side and secure to righthand front wheel with wire.
Note: Protect fender panel from damage.
^ Unbolt lock carrier and place in a secure position.
^ Disconnect wires/connectors as follows:
1 - on ACF valve (in addition, remove ACF valve from air filter housing)
2 - on air mass meter
3 - on Wastegate Bypass Regulator valve N75-
^ Disconnect hose connections, secure wiring aside and remove air filter housing arrows-.
^ Disconnect connector -arrow- at Secondary Air Injection (AIR) Pump Motor -V101-.
- Filling location: Front right in engine compartment underneath air filter housing
^ Disconnect hose -arrow- going to combination valve for secondary air inlet.
^ Remove coolant hoses -1- and -3-.
^ Unbolt coolant expansion tank -2 (-arrows-).
^ Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch F66- on bottom of expansion tank.
^ Remove left hand coolant hose to radiator heat exchanger on bottom coolant pipe to engine.
^ Remove right-hand coolant hose to radiator heat exchanger at connection of cylinder head.
^ Remove air duct hose -1-.
^ Disconnect connector -2- at Charge
^ Air Pressure sensor -G31-.
WARNING! The fuel system is pressurized. Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
^ Disconnect fuel feed pipe -1- and fuel return pipe -2- and move clear.
^ Disconnect vacuum hose -3- to brake servo.
^ Disconnect vacuum hose -4- to ACF valve.
^ Disconnect vacuum hose -5- to vacuum reservoir.
^ Remove clamp -arrow- and disconnect tube.
^ Remove cover for electronics box in plenum chamber -arrows-.
^ Carefully pry off retainer bar with a screwdriver -arrow-.
^ Release connector catch -arrows- and pull off control module connectors -1- and -2-.
^ Release catch -arrow- and remove additional relay carrier in electronic box towards top.
^ Disconnect connectors on rear of console.
^ Disconnect Ground wire -6-.
^ Remove connectors -1 through 5 from bracket.
^ Disconnect connectors -1. and -2- for oxygen sensors.
^ Disengage wiring harness -arrow and move clear to one side.
^ Disconnect connector from speedometer sender -G22- from left of gearbox, pull wiring clear.
Vehicles with manual gearbox
^ Disconnect connector for back-up light switch from gearbox.
All models:
Note: Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If the belt rotates in the wrong direction when it is reinstalled ' this can cause breakage. Ensure that the belt is properly seated on the pulleys when installing.
^ Loosen bolts securing ribbed belt tensioning roller for A/C compressor arrows-. Loosen belt and remove.
CAUTION! The air conditioner refrigerant circuit must not be opened.
^ Remove A/C compressor from bracket and secure to body with wire.
^ To loosen ribbed belt, turn tensioner in direction of arrow.
^ Remove ribbed belt from alternator pulley.
^ Secure pulley for viscous fan with pin punch -1- and unscrew using Allen key -2-.
^ Remove viscous fan from mounting.
^ Remove pulley from power steering pump.
^ Unbolt power steering pump, move clear to one side and tie in place. Do not open hydraulic connections.
^ Remove securing bolts -arrows- of exhaust turbocharger/catalytic converter.
^ Remove gearbox bracket for exhaust system -arrow-.
Note: The isolating element in front exhaust pipe must not be deflected more than 10° to avoid damage.
^ Disconnect exhaust system from connector of exhaust turbocharger.
^ Remove wiring -1- and -2- from starter, remove insulator from positive connection of starter.
^ Unbolt wiring clamp -4-.
^ Remove bracket for starter from cylinder block -3- and from starter.
^ Disconnect starter from gearbox and remove.
^ Disconnect Ground wire from engine support (right side).
Vehicles with automatic gearbox:
^ Use 15 mm wrench socket Matra V/1 75 or equivalent to remove 3 bolts of torque converter in opening for removed starter (give crankshaft 1/3 of a turn in each case).
Note: When loosening torque converter bolts, counterhold crankshaft by applying a wrench to central bolt on vibration damper.
All models:
^ Loosen nuts -arrow- several turns on right and left engine mountings.
^ Mark positions of mountings -1- and locating sleeves -2- on left and right engine mountings (lower).
Note: Different mounting holes are provided for the different engine versions.
^ Remove lower nuts -1- on left and right engine mountings.
^ Lift engine and gearbox slightly with workshop crane V.A.G 1202A.
WARNING! Ensure that components are supported safely - accident risk.
Note: Ensure that wiring and other connections are not damaged at top of bulkhead.
^ Remove engine/gearbox securing bolts accessible from below.
^ Lower engine back down again.
^ Set up support bar 10-222 A behind spring mount location onto fender bolt edge. Spindle is at front.
^ Engage gearbox support 3147 in bolt hole in bell housing on gearbox.
^ Connect gearbox mounting 3147 and support bar 10-222 A with auxiliary hook 10-222 A/2.
^ Remove all but one upper engine/gearbox securing bolts. Leave one bolt in place (hand tight).
^ Attach lifting tackle 2024 A to engine and hook onto workshop crane 1202 A.
Note: To balance the center of gravity of the engine, position the hook attachments as shown in the illustration.
WARNING! The hooks and locating pins of the lifting tackle must be secured with locking pins -arrows in illustration-.
^ Remove last securing bolt.
Note: Check that all hoses and other connections between engine and body have been disconnected.
^ Lift engine with workshop crane V.A.G 1202 A until thread bolts of engine mountings are free.
^ Tension spindle of support bar 10 222 A.
Vehicles with automatic gearbox:
^ Remove gearbox from engine. At the same time, remove torque converter from drive plate.
All models:
^ Remove engine from gearbox and lift forward out of engine compartment.
Vehicles with automatic gearbox:
^ If necessary, secure torque converter in gearbox with wire to prevent it falling out.