Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Drip Tray (VAS 6208)
• Engine/Transmission Jack (V.A.G 1383 A)
• Spring Type Clip Pliers (VAS 5024A)
• Step Ladder (VAS 5085)
• Engine/Transmission Support (T10012)
• Hex Ball Socket (3247)
• Engine Bung Set (VAS 6122)
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
- Remove the engine cover and air filter.
- Remove electrical connector - arrow - for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
- Open the cap of the coolant expansion tank.
- Remove the cover from above battery, by pressing the release button - arrow -.
Danger of causing damage to electrical components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- With ignition switched off, disconnect battery ground (GND) cable - arrow -.
- Remove the battery.
- Remove the battery carrier - arrows -.
- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.
- Pull off and remove wiper arms from wiper axles.
- Unclip the spray nozzles - arrow -.
- Push the spray nozzles, with lines still attached, back through the opening and into the plenum chamber.
- Remove rubber seal - 1 - for plenum chamber cover.
- Remove the plenum chamber cover - 2 -.
- Free up the rear engine wiring harness at the partition for plenum chamber.
- Remove partition for plenum chamber - arrows -.
- Remove engine control module (ECM).
- Separate the electrical connector - 1 - for the engine wiring harness.
- Release pass-through for engine wiring harness - arrow - and pull off upward.
- Open bracket for wiring - arrows -.
- Free up and disconnect the electrical connector - 1 -.
- Open the underlying wiring guide bracket - 2 -.
- Open the wiring guide bracket - 3 -.
- Remove engine wiring harness to control module from wiring.
- Separate the electrical connector - 1 - for the backup lamp switch.
- Remove the ground (GND) cable - 2 -.
- Push cover - 3 - toward rear.
- Remove the wires - 1 and 2 - at the starter and free them up.
- Remove the cover from above the battery, by pressing the release buttons - arrows -.
- Remove the electrical harness - arrow - and free up the wiring to the generator.
- Remove both front wheels.
- Remove noise insulation.
- Remove the left and right noise insulation fasteners - 1 to 3 -.
- Place the (VAS 6208) under engine.
- Drain the coolant, by pulling off the lower coolant hose - arrows -.
- Disconnect upper coolant hose from radiator - 2 -.
- Disconnect coolant hoses to heat exchanger - arrows -.
• The illustration depicts the engine removed from behind.
- Remove the accessible nuts - arrows - for the front exhaust pipe/turbocharger from above.
- Disconnect vacuum hose - arrow - from the brake booster.
- Unclip the lock washers - 1 - and - 2 - at both cables.
- Pull off the cable retainers from the transmission selector lever and relay lever.
- Remove cable mounting bracket from transmission and lay aside - arrows -.
Do not operate the clutch pedal anymore after hose for slave cylinder has been disconnected.
- Pull out clip - 2 - to the stop in direction of the - arrow - and pull off hose line - 1 -.
The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.
- Mark the fuel line - 2 - and the EVAP line - 1 -.
- Disconnect the fuel line - 2 - and lay it free.
- Disconnect the EVAP line - 1 - and lay it free.
- Disconnect the vacuum line - 3 - to EVAP canister (press release buttons).
- Remove EVAP canister upward.
- Disconnect coolant hoses - 1 and 2 -.
- Discharge the air conditioning system.
- Remove A/C line - arrow - from compressor.
- Unscrew the bolts - arrows - of the engine mountings approximately 2 turns.
- Unscrew the bolts - arrows - of the transmission mountings approximately 2 turns.
- Disconnect the electrical connector - 1 -.
- Open the cable retainer - 2 and 3 - and free up the electrical wiring.
- Remove the bolts - 1 - from above.
- Remove the air duct clamps - 1 and 2 - for charge air cooler.
- Disconnect the connector - 2 -.
- Remove bolts - 3 - and remove the fan shroud downward and off.
- Disconnect the connector - 1 - at left longitudinal member and free up the cable.
- Disconnect air guide pipe - arrow - from charge air cooler.
- Remove the A/C pipe from the condenser - arrow -.
- Disconnect the connector from charge air pressure sensor (G31).
- Disconnect the electrical connector on the oil level sensor - 1 -.
- Unclip the retainer - 2 -.
- Disconnect the electrical connector on the after-run coolant pump motor - 3 - and free up the wires.
- Remove heat shield from above the drive axle with the (3247).
- Remove the left and right drive axles.
- Remove the right vehicle underbody cover - arrows -.
- Disconnect the oxygen sensor connector - arrow - after the catalytic converter and free up the wire.
- Remove the remaining nuts - arrows - for the front exhaust pipe/turbocharger from below.
- Remove the supports for front exhaust pipe with catalytic converter, by removing bolts - 1 and 2 -.
• Flex joints in front exhaust pipe must not be bent more than 10°, otherwise they may be damaged.
- Disconnect the exhaust system at the clamping sleeve - arrows -.
- Remove crossmember for vehicle floor - arrows -.
- Remove bracket for exhaust system - arrows -.
- Remove catalytic converter with front exhaust pipe.
- Remove the bolts - 1 to 3 - and the pendulum support.
- Remove auxiliary coolant pump - arrows -.
- Attach the (T10012) to the cylinder block using the bolt - 1 - and nut - 2 - and tighten to approximately 20 Nm.
- Insert the (V.A.G 1383 A) into the (T10012) and lift slightly.
• Use the (VAS 5085) to remove bolts for assembly mounting.
- Remove bolts - arrows - at engine assembly mounting.
- Remove bolts - arrows - at transmission assembly mounting.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
• While lowering, carefully guide engine/transmission assembly in order to prevent damages.
- Pull engine/transmission assembly as far forward as possible and slowly lower it.