Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Support (T10359)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Drip Tray for VAS 6100 (VAS 6208)
• Locking Pin (T10060A)
• Puller (T10369)
• Puller for Removing Wiper Arms (T10369/1)
• Engine Bung Set (VAS 6122)
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.
• Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the (VAS 6122).
There is a risk of injury because the fuel is under very high pressure.
• When removing the engine, the high pressure area of the fuel injection system is not opened.
• If the engine is removed and the high pressure area is opened for the following steps, the fuel pressure in the injection system must be reduced to a residual pressure before opening the high pressure area.
- Reduce fuel pressure in high pressure area.
- Remove the cover for the air guide; to do this, disengage the side clips - arrows -.
- Unclip the lower air guide, to do this, disengage the clips - arrows -.
- Remove both lower air guide and air guide hose.
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Remove the air guide hose - 2 -.
- Remove the bolt - 4 - and the air filter housing.
• Ignore - 3 -.
- Remove the cover over the battery by pressing the release button - arrow -.
Danger of causing damage to other electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- With the ignition turned off, disconnect the Ground (GND) cable - arrow - on the battery.
- Remove the battery.
- Remove the battery tray - arrows -.
- Remove the fan shroud bolts - 1 - from above.
• Ignore items - 2 and 3 -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the connector - arrow - and free up the wire.
• Ignore items - 1 and 3 -.
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.
- Open the coolant reservoir cap.
- Remove both front wheels.
- Remove the noise insulation in the center by loosening the fasteners - 1 and 2 -.
- Open the fasteners - 1, 2 and 3 - and remove the left and right noise insulation.
- Remove the air guide pipe - 1 and 2 -.
- Remove the bolt - 1 - and remove the air guide pipe downward.
• Ignore items - 2, 3, 4 and arrow -.
- Disconnect the connector - 2 -.
- Remove the bolts - 3 - and remove the fan shroud downward.
• Ignore - 1 -.
- Remove air guide hose - arrows -.
- Disconnect the connector - 2 - from the Engine Coolant Temperature (ECT) sensor on radiator outlet (G83).
• Collect escaping coolant in a clean container for disposal or reuse.
- Place the (VAS 6208) under the engine.
- Remove the coolant hose - 1 - by pulling the retaining clip out and letting the coolant drain.
- Remove the coolant hose from the after-run coolant pump (V51) - arrow - and drain the remaining coolant.
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.
Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect fuel supply hose - 2 - by pressing release ring.
- Disconnect the vacuum line - 1 - to the Evaporative Emission (EVAP) canister by pressing the release button.
- Pull the EVAP canister up out of the bracket - arrow - and place it on the engine.
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing the 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 -.
- Remove ribbed belt and release tensioning device.
• Ignore the (T10060 A).
- Remove coolant hoses - 1 and 2 -.
- Disconnect the connector - 1 - from the throttle valve control module (J338).
- Remove bolts - arrows - and remove throttle valve control module (J338).
- Remove the upper coolant hose from the radiator - arrow -.
- Remove the coolant hoses from the heater heat exchanger - arrows -.
- From above, remove the nuts - arrows - on the front exhaust pipe connection to the turbocharger.
- Remove the vacuum hose from the brake booster - arrow -.
- Pry cover caps off the windshield wiper arms with screwdriver.
- Loosen nuts - arrows - a few turns.
- Position the (T10369/1) on the windshield wiper arm - 1 - as illustrated.
- Mount the pressure piece - 2 - on the wiper axle.
- Turn the screw - 3 - clockwise until the wiper arm is pulled off the wiper axle.
- Remove nuts completely and remove wiper arms.
- Unclip the spray nozzles - arrow -.
- Slide the spray nozzles with the lines connected through the assembly opening in the plenum chamber.
- Remove gasket - 1 -.
Danger of causing damage to the plenum chamber cover.
• Coat the transition area between the windshield and plenum chamber cover - 2 - with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.
- Remove plenum chamber cover - 2 - by carefully pulling the cover out of the retainer on the windshield.
- Free up the rear engine wiring harness on the plenum chamber bulkhead.
- Remove the plenum chamber bulkhead - arrows -.
- Remove Engine Control Module (ECM).
- Disconnect the engine wiring harness electrical connector - 1 - - arrow -.
- Release pass-through for engine wiring harness - arrow - and pull off upward.
- Remove E-box cover by slide both latches in direction of - arrow -.
- Remove terminal 30 wiring - arrow - at engine compartment E-box and free up.
- Open wiring router bracket - arrows -.
- Cut off cable ties - 1 -.
- Disconnect the connectors - 1 - and free them up.
- Open the underlying wiring guide bracket - 2 -.
- Take the ECM wiring harness out of the wiring router and lay it on the engine.
• To unclip spiral clip, use (80 - 200).
Vehicles with a Manual Transmission
- Remove cable bracket from transmission - arrows -.
- Unclip the lock washer - 1 - from the shift cable and the lock washer - 2 - from the selector cable.
- Remove the cable retainers and the cables from the transmission shift lever and shift relay lever.
- Tie cables with cable bracket off to side.
- Remove the brace - 1 -.
- Free up the hydraulic pipe to the clutch slave cylinder.
- Remove the clutch slave cylinder - arrows - and set it aside. Do not open the line system.
Risk of damaging clutch slave cylinder.
• Do not press the clutch pedal when the clutch slave cylinder is removed.
- Remove the protective boot cable tie - arrow - if applicable.
- Disconnect the connector - 2 -.
- Fold back the protective boot and remove battery positive wire from the starter solenoid.
- Remove Ground (GND) wire - 1 -.
Vehicles with S-Tronic Transmission
- Disconnect the connectors - 1, 3 and 5 -.
- Remove the protective boot and remove the electrical wire - 2 - from the starter solenoid switch.
- Remove GND wire - 4 -.
All Vehicles
- Disconnect the connector - arrow - on the lower left longitudinal member.
• The illustration shows the installation location from below.
- Loosen the subframe mount bolts - arrows - on the engine approximately two turns.
Vehicles with a Manual Transmission
- Loosen the subframe mount bolts - arrows - on the transmission approximately two turns.
Vehicles with S-Tronic Transmission
- Loosen the subframe mount bolts - arrows - on the transmission approximately two turns.
All Vehicles
- Disconnect solenoid clutch electrical connector - 1 - on Air Conditioning (A/C) compressor.
Refrigerant can cause serious personal injury.
• Do not open the air conditioning refrigerant circuit.
- Remove A/C compressor bolts - arrows -.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Tie up the A/C compressor with the refrigerant lines attached to the longitudinal member.
- Remove the bolt - 2 - on the bracket for the after-run coolant pump.
• The after-run coolant pump stays in the installation position.
• Ignore - 1 and arrows -.
Vehicles with a Manual Transmission
- Disconnect the connector from the back-up lamp switch (F4).
- Remove the nut - 1 - and the electrical wiring bracket.
All Vehicles
- Free up the wiring harness on the body.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Unclip the electrical wiring bracket - 2 - to the oil level thermal sensor on the subframe.
- Disconnect the connector on the Heated Oxygen Sensor (HO2S).
AWD
- Mark position of flexible disc to bevel box flange for reinstallation.
- Remove the driveshaft flexible disc bolts - arrows - from the bevel box while counter holding at the triangular flange with a lever.
The shaft seal - arrow - in the driveshaft flange could be damaged.
• Press driveshaft horizontally as far back and to right side of vehicle as possible.
All Vehicles
- Remove the rest of the nuts accessible from below that connect the front exhaust pipe to the turbocharger - arrows -.
- Remove exhaust system bracket - arrows -.
- Remove the front cross member for the vehicle floor - arrows -.
Risk of damaging decoupling elements.
• Do not bend decoupling elements in front exhaust pipe more than 10°.
- Loosen clamping sleeve - 1 - and push it rearward.
- Remove the front exhaust pipe with the catalytic converter.
- Remove the right drive axle heat shield - arrows -.
- Remove the left and right drive axles from the transmission flange shafts.
- Remove bolts - 1, 2 and 3 - and remove pendulum support.
- Remove the left and right nuts - arrow - and the coupling rod from the stabilizer bar.
Vehicles with S-Tronic Transmission
- Remove the nuts - arrows - on the left control arm.
- If applicable, remove the bolt on the left front level control system sensor (G78) bracket.
- Disengage the control arm from the transverse link.
- Tilt the left suspension strut outward and support it with the extension (2024 A /1) as shown in the illustration.
Loose support components could cause an accident.
• Secure the securing pin and control arm using the securing pin - arrow - and nut - 1 -.
Vehicles with a Manual Transmission
- Secure the left drive axle as high as possible.
• Make sure the drive axle surface protection is not damaged.
All Vehicles
- Remove the nuts - arrows - on the right control arm.
- Disengage the control arm from the transverse link.
- Tilt the right drive axle forward while pressing the engine/transmission subassembly forward.
- Secure the drive axle to the longitudinal member - arrow -.
• Make sure the drive axle surface protection is not damaged.
Vehicles with S-Tronic Transmission
- Remove the bolts on the selector lever cable bracket - 1 -.
- Remove locking washer - 3 - - arrow - and remove selector lever cable from transmission.
• Do not bend or kink the selector lever cable.
• Ignore - 2 -.
All Vehicles
- Tighten the (T10359) to the cylinder block using the bolt - 1 - to approximately 20 Nm.
• The threaded hole in the bolt - 1 - serves to secure the after-run coolant pump (V51).
- Mount the (V.A.G 1383 A) on the (T10359).
- Slightly lift the engine/transmission subassembly.
• Use (VAS 5085) to remove bolts for assembly mounting.
- Remove the engine mount bolts from the engine support - arrows -.
Vehicles with a Manual Transmission
- Remove the transmission mount bolts from the transmission bracket - arrows -.
Vehicles with S-Tronic Transmission
- Remove the transmission mount bolts from the transmission bracket - arrows -.
All Vehicles
- Pull the engine/transmission as far as possible to the front and left and slowly lower it.