Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Support (T10359)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Drip Tray for VAS6100 (VAS 6208)
• Ring Spanner 7-Piece Set (3337)
• Locking Pin (T10060A)
• Puller (T10369)
• 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.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Remove luggage compartment floor covering.
- Remove the rear lid trim panel if the cover for the battery negative pole it located underneath it.
- Release retaining clips - arrows - and remove the negative post cover.
- Loosen the nut a few turns and remove battery terminal - arrow - on Ground (GND) cable from the battery post.
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 coolant reservoir cap.
- Remove the bolts - arrows - and air guide.
• Shown on the 2.0L engine.
- 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 bolts - arrows - and the air filter housing bracket.
• Shown on the 2.0L engine.
- Remove both front wheels.
- Remove the noise insulation.
- Remove the left and right noise insulation - arrows -.
- Remove the frame for the noise insulation.
- Remove the air guide pipe - 1 and 2 -.
- Disconnect the connector - 2 -.
- Remove the bolts - 3 -.
- Disconnect the connector - 2 - from the Engine Coolant Temperature (ECT) sensor on radiator (G83).
• Collect escaping coolant in a clean container for disposal or reuse.
- Place (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.
- Remove the bolt - 1 -.
• Ignore items - 2, 3 and 4 and the arrow -.
- Remove the bolts - 1 - and remove the fan shroud upward.
• Ignore - 2 and 3 -.
- Loosen the hose clamp - 2 -.
- Disconnect the electrical connectors - arrow - and free up the electrical wire.
- Remove the bolt - 4 - and the air guide pipe.
• Ignore - 1 and 3 -.
- Remove the upper coolant hose from the radiator - arrow -.
- Remove the bolts - arrows - on the rear side of the radiator.
- Remove the radiator downward.
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 -.
- Remove ribbed belt and release tensioning device.
• Ignore the (T10060 A).
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the fuel hose - 1 - and free it up.
- Remove the hose - 1 -.
- Release the Evaporative Emission (EVAP) canister - B arrow -, remove it upward - A arrow - and lay it aside.
- Disconnect the coolant hoses - arrows - and move them to the side.
• The installation location is shown with the engine removed.
- Remove the air guide pipe bolt - arrow -.
- Remove the air guide pipe; to do this, loosen the hose clamp - 1 -.
- Press the release buttons and remove the air guide hose - 2 -.
- Remove the coolant hose - 1 -.
- Remove the bolt - 2 -.
- Remove the coolant hoses - 1 and 2 -.
- Remove the bolt - 3 -.
• Be careful of the GND wire - arrow - when installing.
- Remove the heat shield - arrows -.
- 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 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.
- Remove gasket - 1 -.
The plenum chamber cover could be damaged.
• 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 cover out of retainer on windshield.
- Free up engine wiring harness on the back of the plenum chamber bulkhead.
- Remove Engine Control Module (ECM).
- Disconnect the engine wiring harness electrical connector - 1 - - arrow -.
- 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 -.
- 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 the ECM on the engine.
- Secure the ECM against falling down.
- Unclip electrical connector - 2 - from bracket and disconnect.
- Remove the terminal 30 wire - arrow - at the engine compartment E-box and free it up.
• To unclip spiral clip, use (80 - 200).
Metal Selector Relay Lever - B -:
- Remove the lock washer - arrow 1 - from the transmission shift lever - A - and remove the shift cable.
- Remove the lock washer - arrow 2 - from the selector relay lever - B - and then remove the selector cable.
Plastic Selector Relay Lever:
- Remove the lock washer - arrow 1 - and the shift cable.
- Press the retainer - arrow 2 - down as far as the stop and remove the selector relay lever and cable retainer. Move it in the direction of operation.
- Tie cables with cable bracket off to the side.
- Remove the transmission support - A arrows -.
- Remove the clutch slave cylinder - B arrows -, move it to the side and secure it with wire. Do not open the line system.
Do not press the clutch pedal when the clutch slave cylinder is removed.
- Cut off cable ties - arrow - for protective boot - 3 -.
- Disconnect the connector - 2 -.
- Fold back protective boot and remove the battery positive wire from the starter solenoid.
- Remove the GND wire nut - 1 -.
- Remove upper starter bolt.
Vehicles with FWD:
- Remove the right drive axle heat shield - arrows -.
- Remove the left and right drive axles from the transmission flange shafts.
- Remove GND wire - 3 -.
- Cut through the cable tie - arrow - for the protective boot.
- Disconnect the connector - 2 -.
- Fold back the protective boot - 1 - and remove the battery positive wire from the starter solenoid.
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.
- Free up the wiring harnesses - arrows - and disengage the electrical connector - 1 - at the bracket.
AWD Vehicles:
- Remove the right drive axle heat shield from bevel box - arrows -.
- Remove the left drive axle from the transmission flange.
- Remove the right drive axle from the bevel box flange.
- Raise the drive axles and secure them with a cable tie.
• Make sure the drive axle surface protection is not damaged.
- Remove the left nut - 1 - if applicable.
- Remove the left nuts - arrows - for the control arm.
- 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 transverse link with the securing pin - arrow - and nut - 1 -.
Vehicles with S-Tronic Transmission 02E:
- Remove the bolts - 1 - from the cable bracket - 2 -.
- Remove locking washer - 3 - - arrow - and remove selector lever cable from transmission.
AWD Vehicles:
- 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 bolts - 1 and 2 - on the bracket for the oxygen sensor electrical connector under the underbody. Remove the cover.
- Remove the bolt - 3 - and free up the electrical wire to the oxygen sensor.
- Remove the connector coupling - arrow - from the bracket.
- Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) (G130) and free it up.
- Remove the rest of the nuts accessible from below that connect the front exhaust pipe to the turbocharger - arrows -.
- Remove the bolts - arrows -, exhaust system bracket and cross brace.
Risk of damaging decoupling elements.
• Do not bent decoupling elements in front exhaust pipe more than 10°.
- Loosen the nuts - arrows - at the clamping sleeve and separate the exhaust system.
- Remove the front exhaust pipe with the catalytic converter and front muffler.
- Remove bolts - 1, 2, 3 - and remove pendulum support.
- Disconnect the connector - 1 - from the oil level thermal sensor (G266).
- Unclip bracket - 2 - for electrical wiring to oil level thermal sensor from subframe.
- Remove the air guide hose - arrows -.
- Loosen the subframe mount bolts - arrows - on the engine approximately two turns.
- Loosen the subframe mount bolts - arrows - on the transmission approximately two turns.
- Disconnect the Air Conditioning (A/C) compressor regulator valve (N280) - 1 - connector from the A/C compressor.
Refrigerant can cause serious personal injury.
• Do not open the A/C refrigerant circuit.
- Remove the 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 compressor with the refrigerant lines attached to the longitudinal member.
- Attach the (T10359) to the cylinder block with 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 subframe bolts - arrows - on the engine.
- Remove the subframe bolts - arrows - on the transmission.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
• While lowering, carefully guide the engine/transmission assembly in order to prevent damages.
- Pull the engine/transmission as far as possible to the front and left and slowly lower it.