Part 2
Engine, Removing - (Continued)
All:
- Disconnect electrical connectors - 2 - at back of connector strip and free up wiring harness.
- Unbolt electrical wire connection - 1 -.
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box upward.
- Disengage and free up engine wiring harness at E-Box and bulkhead.
- If equipped, remove heat shield for left connectors from bulkhead.
- Remove harness connectors - 1...4 - from bracket at left of bulkhead.
- Disconnect the electrical connectors - 1 - and - 4 -.
- Remove electrical harness connectors - 1...4 - from bracket at right of bulkhead.
- Disconnect electrical harness connectors - 1 -, - 3 - and - 4 -.
- Free up oxygen sensor wiring at left and right.
- Remove left and right connector bracket.
- Remove nut - 2 - from left exhaust pipe/exhaust manifold threaded connection which is accessible from top.
• To improve clarity, shown with the engine removed.
- Remove nut - 2 - from right exhaust pipe/exhaust manifold threaded connection which is accessible from top.
• To improve clarity, shown with the engine removed.
All:
- Disconnect coolant hoses to heater core from rear and right coolant pipe. Remove wiring harness retaining clamps on right side of vehicle.
- Remove engine/transmission connecting screws accessible from top. One screw remains installed hand-tight.
- Pull front engine cover off - arrows -.
• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.
- To tension, swing tensioner ribbed belt in direction of - arrow - using Ribbed Belt Install. Tool (3299) and Claw For Tensioner (3299/1).
- Remove ribbed belt from power-steering pump belt pulley.
- Place old oil collecting and extracting device ( V.A.G 1782) under engine.
- Drain engine oil.
- Remove oil filter - 2 -.
- Remove coolant hose - 3 - from oil cooler.
- Remove oil cooler - 1 -.
- Unscrew bracket for refrigerant line on oil pan - arrow -.
• Shown in illustration on a vehicle with manual transmission.
- Disconnect electrical connector - 1 - for wiring to air conditioning compressor clutch solenoid.
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Remove air conditioning compressor from bracket - arrows -.
- Engage air conditioning compressor together with condenser in vehicle with wiring connected at right of vehicle.
- Remove electrical wiring from generator.
- Remove bolts - arrows - and remove generator.
• If generator is stuck in its bracket, screw in mounting bolt again up to 2 rotations.
• Carefully strike on bolt heads using flat side of hammer - doing this loosens threaded sleeves of generator mount.
- Remove heat shield - 1 - for left and right drive axles.
- Disconnect electrical wires - 1 - and - 2 - from starter.
- Remove Ground (GND) cable - 3 -.
- Remove heat shield - 1 - from solenoid switch.
- Remove bolts - 2 - and - 3 - and remove starter.
Vehicles with 01V automatic transmission:
- Remove 3 bolts - arrow - of torque converter in the opening of the removed starter (turn crankshaft 1/3 rotation in each case).
• To loosen the torque converter bolts, counterhold on vibration damper central bolt.
- Remove front crossmember by removing screws - 1 to 4 -.
• 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 - of left exhaust pipe/exhaust manifold threaded connection, which are accessible from bottom.
• To improve clarity, shown with the engine removed.
- Disconnect front exhaust pipe from left exhaust manifold.
• Exhaust pipe remains in vehicle.
- Remove nuts - 1 - and - 3 - of right exhaust pipe/exhaust manifold threaded connection, which are accessible from bottom.
• To improve clarity, shown with the engine removed.
- Disconnect front exhaust pipe from right exhaust manifold.
All:
- If equipped, remove left Engine Speed (RPM) Sensor (G28) heat shield from transmission and remove screw - arrow -.
- Remove Engine Speed (RPM) Sensor (G28) and lay aside.
Vehicles with manual transmission:
- Disconnect electrical connector - arrow - at Back-Up Light Switch (F4) at right on transmission.
- Free up electrical wiring.
• Shown in illustration on a vehicle with manual transmission 01E All Wheel Drive (AWD).
- If equipped, disconnect electrical connector - arrow - at Speedometer Vehicle Speed Sensor (VSS) (G22) at left of transmission.
• Shown in illustration on a vehicle with manual transmission 01E All Wheel Drive (AWD).
Vehicles with 01J automatic transmission:
- Release electrical connector - A - in direction of - arrow - and remove from transmission.
- Free up the wiring harness.
Vehicles with 01V automatic transmission:
- Swivel securing lever and disconnect transmission wiring harness electrical connector - 1 -.
- Disconnect electrical connectors at Speedometer Vehicle Speed Sensor (VSS) (G22) - 2 - and at Multi-Function Transmission Range (TR) Switch (F125) - 3 -.
All:
- Mark installation position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.
• Depending on the engine version, different fastening holes are utilized.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Loosen nuts - arrow - at top of left and right engine mounts a few turns.
- Remove torque bracket - arrows -.
- Tighten Support (T10062) at torque support threaded holes to 20 Nm.
- Raise engine using Engine/Transmission Jack ( VAG1383A) enough so that lower engine/transmission connecting screws can be removed.
• On vehicles with All Wheel Drive (AWD), make sure front driveshaft joint is not damaged when raising engine.
- Remove bottom engine/transmission connecting bolts - arrows -.
- Lower engine again.
Vehicles with manual transmission or 01J automatic transmission:
- To avoid damaging bolted fender flanges using Engine Support Bridge (10-222A), insert Insert Pad For Front Fender (T40045) on both sides between bolted fender flanges and web plate beneath.
- Position Engine Support Bridge (10-222A) behind gas-filled strut on bolted fender flange.
• The spindle is positioned forward.
- Engage Engine Support Adapter (3147) in middle screw hole on transmission bell housing.
- Connect Engine Support Adapter (3147) with Engine Support Bridge (10-222A).
• To improve clarity, shown with the engine removed.
• If Engine Support Adapter (3147) cannot be inserted far enough into hole on bell housing because wiring routing has changed, use a long screw M10 and Additional Hooks (2) ( 10-222A/2) in place of engine support adapter.
Vehicles with 01V automatic transmission:
- To avoid damaging bolted fender flanges with Engine Support Bridge (10-222A), insert Insert Pad For Front Fender (T40045) on both sides between bolted fender flanges and web plate beneath.
- Position Engine Support Bridge (10-222A) behind gas-filled strut on bolted fender flange.
• The spindle is positioned forward.
- Engage Engine Support Adapter (3147) in left screw hole on transmission bell housing.
- Connect Engine Support Adapter (3147) with Engine Support Bridge (10-222A) and Additional Hooks (2) (10-222A/2).
• To improve clarity, shown with the engine removed.
All:
- Engage Engine Sling (2024A) at Shop Crane -Load Cap=700-1200Kg (VAS6100), as shown in illustration.
• To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
CAUTION!
Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.
- Remove last engine/transmission connecting screw.
• Verify that all hose and line connections between engine and body have been disconnected.
- Raise engine using Shop Crane -Load Cap=700-1200Kg (VAS6100) enough so that engine mounts are free.
- Turn Engine Support Bridge (10-222A) spindle back.
• Ensure no wiring on bulkhead was damaged.
Vehicles with 01V automatic transmission:
- Press transmission off engine, thereby pressing torque converter off drive plate.
All:
- Pull the engine off from transmission and lift it forward and out of the engine compartment.
Vehicles with 01V automatic transmission:
- Secure torque converter in transmission against falling down using Bracket (30-211A).
