Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine/Transmission Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Drip Tray (VAS 6208)
• Locking Pin (T10060 A)
• Assembly Tool (T10118)
• Hose Clamps Up to 25 mm Dia. (3094)
• Torque Wrench (SAT 8010/3)
• Engine mount (T40074)
• Qty. 1 M12 nut
• Qty. 2 M10 bolts
Procedure
• Assemble engine with transmission downward.
• During installation, cable ties must be installed at the same location.
• Collect escaping coolant in a clean container for disposal or reuse.
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- Remove luggage compartment floor covering.
- If the battery negative pole cover is under the rear cross panel trim, remove rear cross panel trim.
- Release retaining clips - arrows - and remove negative pole cover.
- Loosen nut a few turns and remove terminal clamp - arrow - on Ground (GND) cable from battery pole.
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 coolant reservoir cap.
- Remove both front wheels.
- Remove noise insulation in center by loosening mounting sections - 1 through 4 -.
- Remove left and right noise insulation - arrows -.
- Remove noise insulation frame - arrow -.
- Disconnect electrical connector - 1 - on engine coolant temperature (ECT) sensor (on radiator) (G83).
- Place (VAS 6208) under engine.
- Remove coolant hose downward from radiator - arrow - and allow coolant to drain.
- Remove lower coolant hose to after-run coolant pump (V51) - arrow - and allow coolant to drain.
• The illustration shows the coolant hose on a vehicle with direct shift automatic transmission (DSG).
- Remove resonance tube - 2 - from air guide hose.
- Remove air guide hose - 1 - from throttle valve control module (J338).
- Disconnect the electrical connector - 3 - for the mass air flow sensor (G70).
- Detach upper section of air filter housing - arrow - and remove air filter insert.
- Remove bolts - arrows - and remove air duct.
- 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 electrical connector - 2 - for heated oxygen sensor (HO2S) (G39).
- Disconnect electrical connector - 3 - for brake fluid level warning switch (F34).
- Free up electrical wires to oxygen sensors.
- Pry cover caps off windshield wiper arms with screwdriver.
- Loosen nuts - arrows - a few turns.
- Loosen wiper arms in succession by tilting wiper axles slightly.
- Remove nuts completely and remove wiper arms.
• If wiper arms cannot be removed in this way, use a standard puller.
- Remove rubber seal - 1 -.
- Remove plenum chamber cover - 2 - by carefully pulling cover out of retainer on windshield.
- Free up rear engine wiring harness on plenum chamber partition.
- Remove bolt - arrow - and remove engine control module from bracket.
- Disconnect electrical connector - arrow - for body wiring harness - 1 -.
- Release engine wiring harness feed through - 1 - and remove upward - arrow -.
- Remove E-box cover by sliding both latches in direction of - arrow -.
- Open wiring router bracket - arrows -.
- Cut off cable ties - 1 -.
- Unclip electrical connector - 1 - from bracket and disconnect.
- Open wiring router bracket below.
- Unclip engine wiring harness to engine control module from wiring router.
- Place engine wiring harness with engine control module on engine.
- Secure engine control module against falling down.
- Unclip electrical connector - 2 - from bracket and disconnect.
- Remove terminal 30 wiring - arrow - from engine compartment E-box and free up.
• To unclip spiral clip, use (80 - 200).
Manual Transmission
- Cut off cable ties - arrow - for protective boot - 3 -.
- Disconnect electrical connector - 2 -.
- Fold back protective boot and remove B+ wire from starter solenoid.
- Remove Ground (GND) cable - 1 -.
- Remove upper starter bolt.
- Remove cable bracket from transmission - arrows -.
- Unclip lock washer - 1 - from shift cable and lock washer - 2 - from selector cable.
- Remove cable retainers with cables from selector shaft lever or relay lever.
- Tie cables with cable bracket off to side.
- Clamp off pressure line to clutch slave cylinder with (3094).
- Pull fastener upward - arrow - and remove hose/line assembly - 1 - from clutch slave cylinder bleeder.
Risk of contamination from escaping brake fluid.
• If the hose/line assembly is disconnected from the clutch slave cylinder breather, do not press clutch pedal.
Vehicles with DSG transmission:
- Cut off cable ties - arrow - for protective boot - 1 -.
- Disconnect electrical connector - 2 -.
- Fold back protective boot and remove B+ wire from starter solenoid.
- Remove Ground (GND) wire - 3 -.
Risk of destroying control module (Mechatronic) with static discharge.
• Do not touch contacts in transmission connector with hands.
- To discharge static electricity, touch vehicle ground with hand (without gloves).
- Disconnect electrical connector - 4 - by turning twist lock counterclockwise.
All Vehicles
- Remove coolant hoses to heater core from bulkhead - arrows -.
- Remove upper left coolant hose from radiator - arrow -.
There is a risk of injury because the fuel is under high pressure.
• Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.
- Disconnect fuel supply hose - 4 - by pressing release ring.
- Free up fuel supply hose.
- Remove the coolant hoses - 2 - and - 3 -.
- Remove vacuum hose to brake booster - arrow -.
Vehicles with engine code CBRA:
- Disconnect the vacuum hoses from the intake manifold and free them up:
2 To Leak detection pump (LDP) (V144)
4 To Evaporative emission (EVAP) canister purge regulator valve (N80)
- Remove the evaporative emission (EVAP) canister purge regulator valve (N80) from the bracket and lay it to the side.
• Ignore - 1 and 3 - and - arrows -.
All Vehicles
- Remove nuts - 1 - and - 2 - (accessible from top) from front exhaust pipe to exhaust manifold connection.
• Nuts - 3 through 6 - are removed at a later time.
- Remove upper fan shroud bolts - top arrows -.
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.
- To release ribbed belt tension, rotate tensioner in direction of - arrow -.
- Secure tensioner with (T10060 A).
- Remove ribbed belt.
- Loosen subframe mounts bolts on engine - arrows - approximately 2 turns.
- Loosen subframe mounts bolts on transmission - arrows - approximately 2 turns.
Manual Transmission
- Disconnect electrical connector - 2 - on back-up light switch (F4).
- Remove nut - 1 - and bracket with electrical wires from lower starter bolt.
All Vehicles
- Disconnect electrical connector - 1 - at secondary air injection (AIR) pump motor (V101) and free up electrical wiring.
• Ignore - 2, 3 and arrows -.
- Free up coolant hose on bottom of fan shroud.
- Disconnect electrical connectors - 1 - for coolant fan on bottom of fan shroud.
- Remove fan shroud lower bolts - bottom arrows -.
- Remove fan shroud downward with both coolant fans.
- Disconnect solenoid clutch electrical connector - 1 - on A/C compressor.
Risk of injury from refrigerant.
• The air conditioning refrigerant circuit must not be opened.
- Remove A/C compressor bolts - arrows -.
- Secure A/C compressor with connected refrigerant hoses on front of longitudinal member.
- Disconnect electrical connector - 1 - on oil level thermal sensor (G266).
- Unclip bracket - 2 - for electrical wiring to oil level thermal sensor (G266) from subframe.
- Remove right drive axle heat shield from bevel box - arrows -.
- Remove right drive axle.
- Remove left drive axle from transmission flange shaft.
- Remove front exhaust pipe to exhaust manifold connecting nuts - 3 through 6 -.
• Nuts - 1 and 2 - were already removed.
- Remove nuts - 1 - and - 2 - under vehicle floor.
- Remove cover from oxygen sensor electrical connector bracket.
- Remove bolt - 3 - and free up electrical wiring to oxygen sensors.
- Remove electrical connectors from bracket and disconnect:
1. For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) (G130)
2. For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) (G131)
- Remove exhaust system bracket - arrows -.
Risk of damaging decoupling elements.
• Do not bend decoupling element in front exhaust pipe more than 10°.
- Disconnect exhaust system at clamping sleeve - 1 -.
- Remove front exhaust pipes with catalytic converters and front muffler.
- Mark position of flexible disc to bevel box flange for reinstallation.
- Remove driveshaft flexible disc from bevel box - arrows - while counterholding on triangle flange with lever.
Risk of damaging sealing ring - arrow - in driveshaft flange.
• Press driveshaft horizontally as far back and to right side of vehicle as possible.
Vehicles with DSG transmission:
- Remove bracket bolts - 1 -.
- Remove locking washer - 3 - - arrow - and remove selector lever cable from transmission.
• Ignore - 2 -.
All Vehicles
Risk of damaging sealing ring in driveshaft flange.
• Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.
- Remove bolts - 1, 2, 3 - and remove pendulum support.
- Secure the (T40074) to the cylinder block using one M12 nut and two M10 bolts - arrows - tightened to approximately 20 Nm.
- Place (V.A.G 1383 A) on (T40074) and raise engine/transmission assembly slightly.
• To remove subframe mounting bolts, use (VAS 5085).
- Remove subframe mount bolts on engine - arrows -.
- Remove subframe mount bolts on transmission - arrows -.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
• To prevent damage, carefully guide engine/transmission assembly when lowering.
- Pull engine/transmission assembly as far forward as possible and slowly lower it.