Engine, Removing
Engine, Removing
CAUTION!
Due to the factory coating on the cylinder walls, it is imperative the cylinders are NOT honed during any repair!
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Engine and transmission jack (VAG 1383A)
• Spring type clip pliers (VAS 5024A)
• Step ladder (VAS 5085)
• Engine and transmission support (T10012)
• Drip tray for VAS 6100 (VAS 6208)
For information on securing the engine to the engine stand, refer to => [ Engine, Securing on Assembly Stand ] Engine, Securing on Assembly Stand.
• To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the antitheft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut open when removing the engine, must be replaced in the same position when installing engine.
• Seal off the removed fuel, ventilation and vacuum lines so no dirt enters the systems.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
Removing
- With the ignition off, disconnect the battery ground cable.
- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.
- Remove the battery.
- Remove the cover - 1 - for the E-box and remove the wire - 2 -.
- Remove the battery holder bolts - arrows - and battery holder.
- Remove the oxygen sensor (before catalytic converter) electrical connector - arrow - out of the bracket, disconnect the connector and free up the wiring harness.
- Remove the plenum chamber bulkhead.
- Disconnect engine wiring harness electrical connectors from the Engine Control Module (ECM). Refer to one of the following:
• => [ Engine Control Module, without Anti-Theft Protection ] Engine Control Module, without Anti-Theft Protection.
• => [ Engine Control Module, with Anti-Theft Protection ] Engine Control Module, with Anti-Theft Protection.
- Release the pass through for the engine wiring harness - arrow - and pull off upward.
- Open the brackets - arrows - for the wiring.
- Remove the engine wiring harness to control module - 1 - wiring.
- Open the brackets - 2 and 3 - for the wiring.
- Expose the harness electrical connector - 1 - at the left front of the wiring harness and disconnect it.
- Remove the engine wiring harness to control module wiring.
- Disconnect all harness electrical connectors of the engine wiring harness/body and set the engine wiring harness on the engine.
- Disconnect the backup lamp switch electrical connector - 4 -.
- Remove the nut - 3 - and remove the ground wire.
- Disconnect the electrical connector - 1 - , remove the nut - 2 - and remove the wire from the starter.
- Free up the wires.
- Disconnect the vacuum hose - arrow - from the brake booster.
With a Manual Transmission
- Remove the shift mechanism from the transmission.
- Remove the hose/pipe assembly from the slave cylinder, see the transmission removal procedure.
CAUTION!
Do not operate the clutch pedal any more.
With a DSG Transmission
When touching metal parts, it is possible that an electrostatic discharge could occur. The reason for this is the electrostatic charge of the human body. This charge can lead to functional problems by touching the electrical components of the transmission and selector lever mechanism.
- Touch a grounded object, for example, a water pipe or a vehicle hoist, before working on the mechatronic unit.
- Do not make direct contact with the electrical connector terminals.
- Turn the bayonet connection - 1 - of the connector toward the left and pull the connector off from the transmission.
- Release the lock washer - A - and remove upward.
- Pull off the lock washer - B - upward.
- Press off the selector lever cable from selector lever and set it on top.
CAUTION!
The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.
- Mark the hoses - 1, 2 and 3 - and remove them from the lines.
- Disconnect the charge air pipe - 4 -.
- Drain the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Disconnect the coolant hoses - 1 and 2 -.
- Slightly loosen the engine mount to engine mount bracket bolts - arrows - (loosen less than 1 rotation).
- Slightly loosen the transmission mount to transmission mount bracket bolts - arrows - (loosen less than 1 rotation).
- Remove the charge air hoses - arrows -.
- Bring the lock carrier into the service position. Refer to
- For better positioning, place a approximately 80 mm long sleeve, for example, the specialty socket wrench (3353), socket 19 mm (3077) or a sleeve from the holding fixture (VW 540/1A) (old tool) on the right and left sides between the lock carrier and the body.
- Remove the front part of the left wheel housing liner. Remove the bolts - 1 through 3 - to do so.
- Remove the auxiliary coolant pump bracket bolts - arrows - and disconnect the electrical connector.
- Disconnect coolant hoses - arrows - from the heater core at the bulkhead.
With Air Conditioning
- Remove the intake air guide with coolant fans. Refer to => [ Coolant Fan and Coolant Fan 2 ] Service and Repair.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the A/C compressor from the accessory bracket.
- Secure the A/C compressor - 3 - to the lock carrier - 2 - as shown. Place some cardboard - 1 - against the radiator to protect it.
• To prevent damage to condenser and also to the refrigerant lines/pipes, ensure that the pipes and hoses are not stretched, kinked or bent.
- Remove the bolts - arrows - for the coolant pipe and oil dipstick guide tube from the intake manifold and pull the oil dipstick guide tube upward from the engine.
- Disconnect the generator electrical connector - 2 -.
- Remove the generator nut - 1 -, wire and wire clamp nut - 3 -.
- Disconnect the electrical connector - 1 -.
- Free up the wire - 2 - behind the coolant pipe - 3 -.
- Disconnect the electrical connector - 1 -.
- Open the cable brackets - 2 and 3 - and free up the wires.
- Remove the throttle valve control module. Refer to => [ Throttle Valve Control Module ] Removal and Replacement.
- Remove the intake air temperature sensor, - item 23 - in the => [ Intake Manifold Assembly Overview ] Intake Manifold Assembly Overview.
- Disconnect the electrical connector from the turbocharger recirculating valve.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the drive axles.
- Remove the front exhaust pipe with catalytic converter. Refer to => [ Catalytic Converter with Front Exhaust Pipe ] Service and Repair.
- Remove the pendulum support bolt - 1 -.
- Remove the pendulum support bolts - 2 and 3 - and remove the pendulum support.
- Disconnect/unclamp all remaining electrical wires required, from the engine/transmission assembly and set aside.
- Disconnect all other coolant, vacuum and intake hose connections, as necessary from the engine.
- Install the (T10012) to the (VAG 1383A).
- Position the (T10012) on the engine as shown and tighten the bolt - 1 - and nut - 2 -.
• Tightening specification: 20 Nm.
- Gently lift the engine and transmission using the (VAG 1383A).
• Use the (VAS 5085) to remove engine and transmission mount bolts.
- Remove the engine mount to engine mount bracket bolts - arrows - from the top.
- Remove the transmission mount to transmission mount bracket bolts - arrows - from the top.
• A 2nd technician is needed to lower the engine/transmission assembly.
• The engine/transmission assembly must be guided with care to prevent damage while lowering.
• When lowering, be especially careful of the A/C compressor and turbocharger.
- Only lower the engine/transmission assembly slightly, then pull forward as far as possible, turn to the left and continue lowering.