Engine, Removing
Engine, Removing
• The engine is removed toward the front with lock carrier removed.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
• Drained coolant must be stored in a clean container for disposal or reuse.
Work procedure
- On a vehicle with automatic transmission, shift selector lever to position "N".
CAUTION!
Observe procedures for disconnecting battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.
- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
- Remove bracket for noise insulation - arrows -.
- Remove front bumper cover.
- Remove air guides from in front of charge air coolers at left and right - arrows -.
- Place drip tray for workshop crane (VAS 6208) or drip tray (V.A.G 1306) under engine.
- Open drain plug - arrow - from lower left coolant hose and drain coolant.
- Disconnect lower coolant hose from radiator - arrow -.
- Remove air duct hose - 1 - to bottom of left charge air cooler.
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Unhook refrigerant line from bracket - 2 -.
- Remove air duct hose - 1 - to turbocharger at bottom right.
- Remove air duct hose - 2 - to charge air cooler at lock carrier.
- Clamp off hydraulic hoses to power steering system cooling coil using Hose Clamps Up to 25 mm dia. (3094).
- Place old oil collecting and extracting device ( V.A.G 1782) underneath.
- Disconnect hydraulic hoses - arrows -.
Vehicles with automatic transmission:
• Observe the rules of cleanliness for working on automatic transmissions.
• Automatic Transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
• Continuously Variable Transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle
- Place old oil collecting and extracting device ( V.A.G 1782) underneath.
- Disconnect ATF lines - 2 and 3 - at separating point.
- Remove ATF line bracket - 1 - on engine.
All:
- Remove engine cover - arrows -.
- Remove bolts - arrows -.
- Remove air duct - 1 - and - 2 -.
- Disconnect coolant hose - 1 - at top of radiator.
- Disconnect electrical harness connector - 2 - for left and right airbag sensors on lock carrier.
- Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Free up electrical wiring.
- Separate left and right electrical connectors - 3 - of horns - 2 -.
• Ignore - 1 -.
- Remove bumper - arrows -.
- Remove left and right air guides at radiator - arrows -.
- Unclip Outside Air Temperature Sensor (G17) - 2 - from bracket.
- Remove bolts - 3 - and - 4 - and remove power steering system cooling coil.
- Disconnect electrical harness connector - 1 - at High Pressure Sensor (G65).
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrows - for condenser.
• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that lines and hoses are not stretched, kinked or bent.
- Pivot condenser downward with lines connected.
- Remove bolts - arrows - at left and right side of bumper.
- Unhook cable for hood release at lock.
- Pull off hood seal from lock carrier and fender edges.
- Remove bolts - arrows - at left and right impact absorbers.
• A second technician is required to remove lock carrier.
- Remove lock carrier and set aside so it cannot topple.
• Before removing ribbed belt, mark turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.
- Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
- Secure tensioning element using Locking Tool ( T40098).
- Remove ribbed belt.
- Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor (G266).
- Remove bracket for refrigerant line on oil pan - arrow -.
- Separate 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 -.
• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Hang up air conditioning compressor and condenser with attached lines on right side of vehicle.
- Unfasten Ground (GND) cable - 1 -.
- Disconnect vacuum line to brake booster at bulkhead - 2 -.
- Disconnect EVAP hose - 3 -.
- Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.
- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.
- Separate electrical connector from Charge Air Pressure Sensor (G31) - 1 -.
- Remove left charge air hose - 2 -.
- Remove right charge air hose - 1 -.
- Pull electrical connector - 1 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) (G130) and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) (Z29) (brown connector) out from retainer
- Pull electrical connector - 2 - for Heated Oxygen Sensor (HO2S) (G39) and Oxygen Sensor (O2S) Heater (Z19) (black connector) out from retainer
CAUTION!
Before opening a component of the high-pressure section, the fuel pressure must be released. Pay absolute attention to the procedure.
- Disconnect fuel line - arrow - (catch escaping fuel and plug open lines immediately).
- Disconnect coolant hoses to heater core on rear of engine.
- Remove windshield wiper arms.
- Remove cowl.
- Remove cover for E-Box in plenum chamber, by removing bolts - arrows -.
- Carefully pry off retainer bar with a screwdriver - arrow -.
- Remove electrical cable - 1 -.
- Disconnect electrical connectors - 2 to 4 - in E-box.
- Unclip fuse carrier - arrows -.
- Free up cable and lay it aside on engine with Engine Control Module (ECM) (J623) connected.
- Remove threaded connections - 1 - of power steering pump through holes in belt pulley.
- Remove threaded connection - arrow - on backside of power steering pump.
- Disconnect connector - 1 and 2 - and free up cable.
- Separate intake hose - 3 - for air filter/turbocharger.
- Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor (G70).
- Free up wiring harness on air filter housing and remove air filter housing - arrow -.
- Remove Ground (GND) cable - arrow - from right longitudinal member.
- Remove heat shield - 1 - for right drive axle.
• Exhaust system decoupling element must not be bent more than 10°, otherwise it may be damaged.
- Loosen clamping sleeve - arrow - and push it rearward.
- Separate front exhaust pipe/catalytic converter - arrows -.
- Remove bolt - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.
- Disconnect connector - arrow - from Back-Up Light Switch (F4) and free up cable to wiring harness.
- Disconnect accessible engine/transmission threaded connections - 1 to 3 - and - 7 to 11 - from below.
- Remove starter and pivot it aside.
- Disconnect electrical connector - 3 -.
- Remove nut - 1 - for clamp.
- Remove nut - 2 - and remove electrical wiring.
- Remove starter.
- Mark installed position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.
• Depending on engine version, different fastening holes are utilized.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Loosen upper nut - arrow - on left engine mount several turns.
- Hook engine sling (2024 A) onto engine and onto workshop crane (VAS 6100) as shown in the 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 the engine sling must be secured with securing pins.
- Remove last engine/transmission connecting bolt.
• Verify that all hose and line connections between engine and body have been disconnected.
- Lift engine until engine mount studs are free.
- Lift floor jack until transmission is supported.
- Pull engine off from transmission and lift it forward and out of engine compartment.