Engine, Removing

Engine, Removing

Special tools, testers and auxiliary items required

• Tensioning strap (T10038)

• Locking pin (T10060A)

• Engine support (T10359)

• Torque wrench 5-50 Nm (VAG 1331)

• Torque wrench 40-200 Nm (VAG 1332)

• Engine and transmission jack (VAG 1383A)

• Step ladder (VAS 5085)

• Engine bung set (VAS 6122)

• Drip tray for VAS 6100 (VAS 6208)

• Hose clip pliers (VAS 6362)

• Cable tie

• To perform this procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti theft code beforehand.

• The engine is removed downward, 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 the engine.

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 fluid 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.

- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal.

- Remove the engine cover. Refer to --> [ Engine Cover ] Engine Cover.

- Remove the air filter. Refer to --> [ Air Filter ] Air Filter.

CAUTION!
Risk of destroying electrical components when battery is disconnected:

• Observe measures when disconnecting battery.

- With the ignition off, disconnect the ground cable - arrow -..





- Remove the battery, battery tray bolts - arrows - and tray.





- Disconnect the left engine wiring harness electrical connector to the Engine Control Module (ECM):

• Without anti theft ECM, refer to --> [ Engine Control Module, without Anti-Theft Immobilizer ] Engine Control Module, without Anti-Theft Immobilizer.

• With anti theft ECM, refer to --> [ Engine Control Module, with Anti-Theft Immobilizer ] Engine Control Module, with Anti-Theft Immobilizer.

- Remove the charge air pipe to noise generator. Refer to --> [ Charge Air Pipe to Noise Generator ] Service and Repair.

- Release the pass through for the engine wiring harness - arrow - and remove upward.





- Remove the E-box cover by sliding both latches in the - direction of arrows -.





- Disconnect the nut and cable - A - for the generator and the nut and cable - B - for the battery - B - from the fuse holder.





- Remove the bolt and ground cable - arrow - from the longitudinal member.





- Open all the cable guide locking mechanisms - arrows - on the longitudinal member.





- Free up and disconnect the electrical connector - 1 -.





- Open the underlying wiring guide bracket - 2 -.

- Remove the ECM wiring harness out of the wiring router and lay it on the engine.

- Remove the noise insulation.

With a Manual Transmission

- Remove the shift mechanism from the transmission..

- Pinch off the hose leading to the clutch master cylinder using the (3094).





- Pull the clamp - arrow - for the hose/pipe assembly - A - up to the stop.





- Pull the hose/line assembly - A - out of the ventilator/slave cylinder and seal it off.

CAUTION!
Do not operate the clutch pedal any more.

With a DSG Transmission

- Disconnect the selector lever cable from the transmission.

Continuation for All





- Disconnect the electrical connector - 2 -.

- Remove the upper bolts for the fan shroud - arrows -.





- Loosen the hose clamp - 2 -.





- Remove the charge air pipe bolt - 4 -.

- Disconnect the electrical connector - arrow - from the charge air pressure sensor and free up the wire.

CAUTION!
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 the coolant reservoir cap with a cloth and carefully opening.

- Open the cap on the coolant expansion tank.

- Remove the front wheels.

- Remove the front wheel housing liners.

- Remove the charge air hoses - arrows -.





- Remove the bolt - 1 - and remove the charge air pipe downward.





- Disconnect the electrical connector - 1 - and remove the lower bolts - arrows - for the fan shroud.





- Remove the fan shroud downward.

- Disconnect the electrical connector - 2 - for the Engine Coolant Temperature (ECT) sensor (on radiator).





• Collect leaking coolant in a clean container for disposal or reuse.

- Place the (VAS 6208) under the engine.

- Drain the cooling system. Refer to --> [ Draining and Filling ] [1][2]Cooling System, Draining and Filling.

- Remove the coolant hoses - 1 and 2 -.





CAUTION!
• The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin.

• Before loosening the connections, place cloths around the connection point. Then release pressure by carefully separating the line.

- Disconnect the lines on the supply location and catch any fuel coming out with a cloth.





1. Ventilation line (press the circlip to release the line).

2. Vacuum line (press the circlip to release the line).

3. Fuel supply line (pull the circlip upward to release the line).

- Remove the upper coolant hose - arrow - from the radiator by removing the securing clip.





- Disconnect the heat exchanger coolant hoses - arrows -.





- From the top, remove the front exhaust pipe to turbocharger nuts - arrows -.





- Disconnect the vacuum hose from the brake booster.

- 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 --> [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.

- Remove the ribbed belt. Refer to --> [ Ribbed Belt ] Ribbed Belt.

- Disconnect the solenoid clutch electrical connector - 1 - from the Air Conditioning (A/C) compressor.





CAUTION!
Risk of injury from refrigerant:

• The air conditioning refrigerant circuit must not be opened.

- Remove the A/C compressor bolts - arrows -.

CAUTION!
Risk of damaging the refrigerant lines and hoses:

• Do not stretch, kink or bend the refrigerant lines and hoses.

- Remove the bolt - 2 - for the after run coolant pump bracket.





• The after run coolant pump stays in the installed position.

- Remove the pendulum support bolts - 1 through 3 - and remove the pendulum support.





- Disconnect the vacuum hoses - arrows -.





- Remove all remaining electrical wires necessary, from engine/transmission and set aside.

- Disconnect all coolant, vacuum and intake hoses from the engine.

- Install the (T10359) to the cylinder block using the bolt - 1 - to approximately 20 Nm.





• The threaded hole for the bolt - 1 - serves to secure the after run coolant pump.

- Install the (VAG 1383A) to the (T10359).

- Lift the engine/transmission assembly slightly.

• Use the (VAS 5085) to remove the bolts for the engine and transmission mounts.

- Remove the engine mount bolts - arrows -.





With a Manual Transmission





- Remove the transmission mount bolts - arrows -.

With a DSG Transmission





- Remove the transmission mount bolts - arrows -.

Continuation for All

• Verify that all hose and line connections between the engine, transmission and body have been disconnected.

• While lowering, carefully guide the engine/transmission assembly in order to prevent damages.

With a DSG Transmission

• Pay attention to the selector lever cable.

Continuation for All

- Pull the engine/transmission as far as possible to the front, left and slowly lower it.

Secure the engine on the (VAS 6095) whenever working on it. Refer to --> [ Engine, Securing to Assembly Stand ] Engine, Securing to Assembly Stand.