Engine, Removing
Engine, Removing
Pry Lever - Rmv Outside Mirror (80 - 200)
Engine/Transmission Jack (V.A.G 1383 A)
Step Ladder (VAS 5085)
Drip Tray for VAS6100 (VAS 6208)
Mandrel (T10060 A)
Assembly Tool (T10118)
Torque Wrench (SAT 8010/3)
• 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.
• Heat insulation sleeves removed during engine removal should be reinstalled in the same location when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
Observe safety precautions when disconnecting the battery.
- Remove tool formed insert under luggage compartment floor covering.
- Remove cover - arrow - for battery compartment
- Remove formed insert from over the battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- Remove center noise insulation fasteners - 1 to 3 -.
- Remove the left and right noise insulation fasteners - 1 to 3 -.
- Disconnect electrical connector - 1 - at engine coolant temperature (ECT) sensor (on radiator) (G83).
- Place (VAS 6208) under engine.
Vehicles with drain plug:
- Turn drain plug - arrow - on radiator left, place assisting hose on supports if necessary.
All Vehicles
- Remove lower coolant hose - 2 - from radiator by removing retaining clamps.
- Drain coolant.
- Also remove lower coolant hose to after-run coolant pump (V51) - arrow - and allow remaining coolant to drain.
• Shown in illustration on vehicle with Direct Shift Gearbox transmission.
- If equipped, remove vacuum hose - 2 - to air guide hose.
- Disconnect air guide hose - 1 - at throttle valve control module (J338).
- Disconnect mass air flow (MAF) sensor (G70) electrical connector - 3 -.
- Remove upper section of air filter housing - arrows -.
- Remove filter element.
- Pull off air guide cover - 1 -, disengage clips sideways to do so.
- Unclip air duct - 2 -.
- Remove lower section of air filter housing - arrows -.
- Remove air filter housing bracket - arrows -.
- Disconnect electrical connector - 1 - for heated oxygen sensor (HO2S) 2 (G108) and - 2 - for heated oxygen sensor (HO2S) (G39).
- Free up electrical wiring to oxygen sensors.
- Pry off the caps on the wiper arms using a screwdriver.
- Loosen the nuts - arrows - by several turns.
- Loosen the wiper arms by gently rocking the wiper arm. Remove the nuts and remove the wiper arms.
- Unclip the spray nozzles - arrow -.
- Push spray nozzle with lines still attached back through opening and into 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 - 2 - for engine wiring harness.
• Electrical connector - 1 - remains connected.
- Release pass-through for engine wiring harness - arrow - and pull off upward.
Vehicle with E-box, old version:
- Press retaining clamps in direction of - arrow - and remove engine compartment E-box cover.
Vehicle with E-box, new version:
- Press both latches in direction of - arrow - and remove engine compartment E-box cover.
- Remove terminal 30 wiring - arrow - at engine compartment E-box and free up.
- Open bracket of wiring - arrows -.
- Free up electrical connector - 1 - and disconnect.
- Open the underlying wiring guide bracket - 2 -.
- Remove engine wiring harness to control module from wiring.
• To unclip spiral clip, use (80-200).
- Disconnect secondary air hose at position indicated by - arrow -.
- Free up air hose to Secondary Air Injection (AIR) pump.
- Disconnect electrical harness connectors - 1 -, - 3 - and - 5 -.
- Remove protective boot and remove electrical wiring - 2 - at starter solenoid switch.
- Remove Ground (GND) cable - 4 -.
- Remove bolts - 1 - for bracket - D -.
- Remove retaining clip - A - upward - arrow - and remove selector lever cable from transmission.
• Ignore items - B - and - C -.
- Remove coolant hoses to heater core on bulkhead - arrows -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Disconnect electrical connection - 1 - at throttle valve control module (J338).
- Disconnect coolant hoses at positions indicated by - arrows -.
- Remove throttle valve control module (J338) from intake manifold - arrows -.
Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Disconnect following hose connections:
1. Coolant hose to reservoir
2. Vacuum hose to Evaporative Emission (EVAP) Canister
3. Vacuum hose to Leak Detection Pump
4. Fuel supply line
5. Coolant hose to reservoir
• Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap - 1 - and slide release button - 2 - to the rear.
- Remove hoses and electrical connectors at indicated places:
1 Electrical connector to evaporative emission (EVAP) canister purge regulator valve (N80)
2 Vacuum hose to brake booster
3 Vacuum hose to exhaust flap, also to Leak Detection Pump
5 Vacuum hose to evaporative emission (EVAP) canister purge regulator valve (N80)
• Ignore - 4 -.
- Remove wiring connection - arrows -.
- Remove wiring connections with coolant and vacuum hoses.
- Remove heated oxygen sensor (HO2S) 2 (G108) - 1 - and heated oxygen sensor (HO2S) (G39) - 2 -.
- Remove bolts - 1 - and - 3 - and remove front exhaust pipe support - 2 -.
- Remove front exhaust pipe nuts and exhaust manifolds - arrows -.
- Remove top mounting bolts for fan shroud - top arrows -.
• Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.
- Swing tensioning device in direction of - arrow - to relieve tension on the ribbed belt and then lock it in place using the (T10060 A).
- Remove ribbed belt.
- Loosen subframe mounting bolts to engine - arrows - approximately 2 turns.
- Loosen subframe mounting bolts to transmission - arrows - approximately 2 turns.
- Remove the right vehicle underbody cover - arrows -.
- Disconnect electrical connector - 1 - to oxygen sensor (O2S) behind three way catalytic converter (TWC) (G130) and - 2 - to oxygen sensor (O2S) 2 behind three way catalytic Converter (TWC) (G131).
- Remove connector coupling from bracket and free up wiring to oxygen sensors.
- Remove front vehicle floor crossmember by removing nuts - 1 - and - 2 -.
• Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.
- Separate exhaust system at clamping sleeve - 3 -.
- Remove exhaust system bracket - arrows - and remove exhaust system.
- Free up coolant hose at bottom on fan shroud.
- Disconnect electrical connector - 3 - at secondary air injection (AIR) pump motor (V101) and free up electrical wiring.
- On vehicles with DSG transmission, remove coolant pipe bracket - 2 - to transmission oil cooler.
- Remove bolts - 1 -.
- Loosen bolt - 4 - and remove Secondary Air Injection (AIR) pump with bracket.
- Disconnect electrical harness connectors - 1 - for coolant fans at bottom on fan shroud.
- Remove mounting bolts for fan shroud at bottom - bottom arrows -.
- Pull out fan shroud downward with both fans.
- Disconnect electrical harness connector - 1 - for A/C clutch on A/C compressor and free up electrical wire.
The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrow - for A/C compressor.
- Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.
- Remove electrical wire - 1 - on generator.
- Separate the electrical connector - 2 -.
• Ignore - 3 -.
- Remove upper idler roller - 1 -.
- Remove mounting bolts - 2 - and - 3 - for generator.
• Generator can be removed from bracket only with the upper mounting bolt still installed.
- Remove generator from accessory assembly bracket.
- Remove generator downward and to the left.
- Disconnect electrical connector - arrow - to secondary air injection (AIR) solenoid valve (N112).
To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Have a second technician press brake pedal.
- Remove collar bolt - 2 - at right drive axle - 1 -.
- Remove right drive axle heat shield from bevel box - arrows -.
- Remove right drive axle.
- Remove left drive axle from transmission flange shaft.
- Position of flexible disc and bevel box flange are marked to each other.
- Remove driveshaft flexible disc at bevel box - arrows -.
• To loosen bolts, counterhold at driveshaft flange/final drive with a lever.
- Press driveshaft horizontally as far back as possible.
• Seal - arrow - in driveshaft flange must not be damaged when removing engine/transmission assembly. If seal is damaged, driveshaft must be replaced.
• Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.
- Remove bolts - 1 to 3 - and remove pendulum support.
- Disconnect electrical connector - 1 - at oil level thermal sensor (G266).
- Unclip bracket - 2 - for electrical wire to oil level thermal sensor (G266) at subframe.
- Disconnect electrical harness connector - arrow - at after-run coolant pump (V51).
- Pull after-run coolant pump (V51), with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.
• Coolant pump remains on the engine with coolant hoses connected.
- Remove bolts - 1 to 5 - and remove accessory assembly bracket.
- Screw (T40074) to cylinder block - arrows - and tighten to 20 Nm.
- Insert (V.A.G 1383 A) at (T40074) and raise engine/transmission slightly.
• Use (VAS 5085) to remove bolts for assembly mounting.
- Remove subframe mounting bolts at engine - arrows -.
- Remove subframe mounting bolts at transmission - arrows -.
• 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.