Part 2 of 2
- Remove harness connectors -1 to 4- from bracket at right of bulkhead.
- Disconnect electrical harness connectors -1, -2- and -4-.
- Expose oxygen sensor wires.
- Remove bracket for harness connectors.
- Remove nut -2- for left exhaust pipe manifold, which is accessible from top.
Note: Illustration is shown with engine removed.
- Remove nut -2- for front exhaust pipe/right 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 heat shield -1- for left and right drive axle.
- Remove electrical wires -1- and -2 from starter.
- Disconnect Ground (GND) connection -3-.
- Remove heat shield -1- from magnetic switch.
- Unscrew bolts -2- and -3- and remove starter.
Vehicles with automatic transmission 01V:
- Unscrew 3 Torx bolts (arrow) of torque converter in the opening of the removed starter (turn crankshaft 1/3 rotation in each case).
Note: To loosen the torque converter bolts counterhold the main harmonic balancer bolt.
All:
Note: Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.
- Disconnect exhaust system at double clamps (arrows).
- Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold, which are accessible from bottom.
Note: Illustration is shown with engine removed.
- Expose oxygen sensor wires.
- Pull front exhaust pipe off of left exhaust manifold.
- Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold, which are accessible from bottom.
Note: Illustration is shown with engine removed.
- Expose oxygen sensor wires.
- Pull front exhaust pipe off of right exhaust manifold.
Vehicles with manual transmission:
- Where installed, unbolt heat shield for engine speed (RPM) sensor.
- Remove Engine Speed (RPM) sensor G28- on left of transmission (arrow) and lay to side.
- Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.
Note: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.
- Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) - G22 at left of transmission.
Note: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.
Vehicles with automatic transmission 01J:
- Disengage harness connector -A- in direction of arrow and disconnect it from transmission.
- Move wiring harness clear.
Vehicles with automatic transmission 01V:
- Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS).
All:
- Unbolt angle bracket for wiring harness from left engine mount.
- Mark installation positions of threaded connections -1- and positioning sleeves -2 below on engine mounts at right and left.
Note: Different mounting bores are available depending upon the installed engine.
- Remove nuts 1 at bottom on left and right engine mounts.
- Loosen nuts (arrow) on top at left and right engine mounts several turns.
- Unbolt torque support (arrows).
- Tighten T10062 support on the threaded bores for torque support to 20 Nm.
- Lift engine using VAG1383A engine/gearbox jack just far enough so that the connecting bolts at engine/transmission can be removed from below.
Note: When working on a vehicle with all wheel drive, make sure the front constant velocity joint for the drive shaft is not damaged when lifting engine.
- Remove bottom engine/transmission connecting bolts (arrows).
- Lower engine again.
- Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
- Hook 3147 engine support adapter into bolt hole at left of transmission housing.
- Connect 3147 engine support adapter and 10222A engine support bridge with 10222Al2 additional hook.
Note: Illustration is shown with engine removed.
- Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration.
Note: To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.
WARNING: Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
- Remove final mounting bolt.
Note: Verify that all hose connections and line connections between engine and chassis have been disconnected.
- Using VAS6100 or VAG1202A workshop crane, lift engine far enough until the threaded bolts of the engine mount are free.
- Turn 10-222A engine support bridge shaft.
Note: Make sure no lines are damaged at bulkhead.
Vehicles with automatic transmission 01V:
- Press transmission off engine, while pressing torque converter off of drive plate.
All:
- Pull engine off of transmission and lift it out of engine compartment toward the front.
Vehicles with automatic transmission 01V:
- If necessary, secure torque converter in transmission from falling out using wire.