Part 1 of 2
Engine, removing and installing
Special Tools and Equipment
^ 10-222A Engine support bridge
^ 2024A Engine Sling
^ 3147 engine support adapter
^ 3299 ribbed belt installation tool with 3299/1 claw for tensioner
^ VAG 1306 drip tray for VAG 1202A engine/transmission hoist
^ VAG 1202A workshop crane
or
^ VAS 6100
^ T10062 support
^ Oil receptacle
Removing
Note:
^ Engine is removed toward the front without transmission and with the lock carrier removed.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.
^ Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
^ Drained coolant must be stored in a clean container for disposal or reuse.
Vehicles with automatic transmission
^ Shift selector lever into position "N".
All:
WARNING: Observe safety precautions when disconnecting the battery.
^ Pull off rubber seal of plenum chamber cover in direction of arrow.
^ Remove cover -1- toward front.
^ Disconnect battery Ground (GND) strap (arrow) with the ignition switched off.
WARNING: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
^ Open cap of coolant expansion tank.
^ Remove both front wheels.
^ For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater on noise insulation.
^ Remove bolts or quick-release screws -1- and -2- and remove front noise insulation.
^ Remove quick-release screws -3- and remove rear noise insulation, if present.
^ Remove bracket for noise insulation (arrows).
^ Remove front bumper:
Vehicles with drain plug:
^ Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.
Vehicles without drain plug:
^ Remove retaining clamp for Engine Coolant Temperature (ECT) Sensor (on Radiator) -G83-.
^ Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.
All:
^ Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.
^ Disconnect left coolant hose from radiator (arrow).
^ In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
^ Place oil pan underneath.
^ Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).
Vehicles with automatic transmission
Note: Observe the rules of cleanliness for working on automatic transmissions:
^ Place oil pan underneath.
^ Remove union nuts -3- and disconnect ATF lines.
^ Remove bracket for ATF lines, to do so remove nuts -1- and -2-.
All:
^ Remove cover -1- in engine compartment (right side).
^ Remove bolts (arrows).
^ Detach Evaporative Emissions (EVAP) Canister Purge Regulator Valve -N80 -1- at air guide.
^ Remove air guide -2-.
^ Remove cover -1- in engine compartment (left side).
^ Disconnect top coolant hose -1- from radiator.
^ Remove electrical harness connector -2- for left and right airbag sensors on bumper.
^ and move cables clear.
^ Remove electrical harness connectors -1- and -2- from bracket and disconnect them.
^ Disconnect electrical harness connector (arrow) for headlights at both sides of the vehicle.
^ Remove air guides from left and right of radiator (arrows).
^ Unclip temperature sensor -2- for outside temperature display from bracket.
^ Unscrew bolts -3- and -4- and remove power steering cooling coil.
^ Disconnect harness connector -1- at High Pressure Sensor -G65-.
WARNING: Do not open refrigerant circuit for A/C system.
^ Remove condenser mounting bolts (arrows).
Note: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
^ Carefully swing condenser downward and move aside.
^ Remove bolts (arrows) on left and right sides of bumper.
^ Unhook hood cable from lock and move cable free.
^ Unscrew bolts at impact absorbers (arrows) at left and right.
Note: A second technician is required to remove the lock carrier.
^ Remove lock carrier and set aside so it cannot topple.
^ Remove rear engine cover (arrows).
^ Remove bolts for holding plate -3- for solenoid valves (arrows).
^ Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
^ Remove hose -4- of crankshaft housing ventilation from air duct -2-.
^ Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
^ Disconnect hose -1- from air guide if installed.
Note: Illustration depicts air guide with the removed engine from rear.
^ Remove coolant hoses -1- and -2-.
Note: Coolant hose -3- remains connected.
^ Remove coolant reservoir (arrow)
^ Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
^ Disconnect Ground (GND) -2-.
^ Disconnect vacuum hoses -1- and -3-.
^ Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.
Vehicles with automatic transmission
^ Disconnect electrical harness connector (arrow).
All:
^ Place oil pan underneath.
^ Disconnect hose -1- from power steering fluid reservoir.
^ Disconnect vacuum hose -2- to vacuum reservoir.
^ Disconnect electrical harness connector (lower arrow) at Secondary Air Injection (AIR) Pump Motor -V101- and move cable free.
^ Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) (upper arrow).
^ Remove the following lines/harness connectors:
1-At Evaporative Emissions (EVAP) canister purge regulator valve -N80
2-Vacuum hose at Evaporative Emissions (EVAP) canister purge regulator valve -N80
3-at Mass Air Flow (MAF) sensor -G70
WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
^ Disconnect fuel supply line -4- and fuel return line -5- and set aside.
^ Disconnect hose connections, move wires free and remove air filter housing (arrows).
Note: Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.
^ Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect the line at the height of right cylinder head -2-.
^ Lever off both covers -3- using a screwdriver.
^ Loosen hex-nuts -4- by several turns.
^ Loosen wiper arm -2- by lightly tilting from wiper axle.
^ Remove hex nuts completely and remove wiper arms.
^ Disconnect securing clips -1- and remove cowl grill -5-.
Vehicles with automatic transmission
^ Disconnect electrical harness connector (arrow) at Brake Booster Pressure Sensor-G294-.
All:
^ Remove heater core E-box cover (arrows).
^ Using a screwdriver, pry off retaining bracket (arrow).
^ Disengage connector catches (arrows) and disconnect harness connectors -1- and -2- from Engine Control Module (ECM).
Vehicles with automatic transmission 01V:
^ Unclip Transmission Control Module (TCM) retaining bracket.
^ Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).
All:
^ Disconnect rear connectors -2- on connector strip and set wiring harness aside.
^ Unbolt electrical wire connection -1-.
^ Disengage locking mechanisms (arrows) and remove secondary relay carrier in E-Box toward top.
^ Unhook engine wiring harness at E-box and at bulkhead and move it free.
^ Remove heat shield for harness connectors at left of bulkhead, if installed.
^ Remove harness connectors -1 to 4- from bracket at left of bulkhead.
^ Disconnect electrical harness connectors -1- and -4-.
^ Expose oxygen sensor wires.
^ Remove bracket for harness connectors.
^ Remove harness connectors -1 to 4- from bracket at right of bulkhead.
^ Disconnect electrical harness connectors -1-, -3- and -4-.
^ Expose oxygen sensor wires.
^ Remove bracket for harness connectors.
^ Remove nut -2- for left exhaust pipe/ exhaust manifold which is accessible from top.
Note: Illustration is shown with engine removed.
^ Remove nut -2- for right exhaust pipe/ exhaust manifold which is accessible from top.
Note: Illustration is shown with engine removed.
^ Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on the right side of the vehicle.
^ Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.
^ Remove front engine cover (arrows).
Note: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.
^ Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
^ Remove ribbed belt from pulley of power steering pump.
^ Place engine oil drip tray beneath engine.
^ Drain engine oil.
^ Remove oil filter -2-.
^ Place VAG1306 Drip Tray beneath engine.
^ Remove coolant hose -3- from oil cooler.
^ Remove oil cooler -1-.
^ Unbolt bracket for refrigerant line at oil pan (arrow).
Note: Depicted in illustration for a vehicle with manual transmission.
^ Disconnect harness connector -1- of electrical wire to clutch for A/C compressor.
WARNING: Do not open refrigerant circuit for A/C system.
^ Unbolt A/C compressor from bracket (arrows).
^ Hang A/C compressor together with condenser with connected lines at right side of vehicle.
^ Disconnect electrical lines from generator.
^ Unscrew bolts (arrows) and remove generator.
^ Remove left and right heat shields for drive axles -1-.
^ Remove electrical wires -1- and -2- from starter.
^ Disconnect Ground (GND) wire -3-.
^ Remove heat shield -1- from magnetic switch.
^ Unscrew bolts -2- and -3- and remove starter.