Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Tensioning Strap (T10038)
• Locking Pin (T10060 A)
• Engine Support (T10359) with Pin (T10359/2)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Sealing Tool (T10249)
• Guide Pins (T10093)
• Adapters for Service Position (T10467)
• Cable Tie
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
• Seal the disconnected fuel and ventilation lines to prevent dirt from getting into the systems.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
• If the engine oil must be drained because of work performed on the removed engine, it should be drained when the engine is still installed. If the engine hangs on the engine lateral bracket (T03001) , the engine is not in its installed position and less engine oil will drain out.
• It is advisable to remove the front wheels before removing the engine and transmission assembly. The vehicle can be lowered on the hoist until the brake cover plates are just above the floor. This enables the most ergonomic work position regarding accessibility of components in the engine compartment.
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 and vacuum) and electrical wiring 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 of all control modules. Refer to the vehicle diagnostic tester.
- Remove the engine cover. Refer to => [ Engine Cover ] Service and Repair.
- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.
- Remove the connecting pipe from the Mass Airflow (MAF) sensor.
- Press the release buttons, remove the intake hose - 1 - and move it to the side.
- Remove the charge air pipe bolt - arrow -.
- Remove the charge guide pipe, to do this, loosen the hose clamp - 2 -.
- Remove the battery and the battery tray.
- Remove the E-box cover inside the engine compartment - arrows -.
- Remove the nut and wire - 2 -.
- Disconnect the connector - 1 - from the Engine Control Module (ECM) and free up the engine wiring harness. Refer to => [ Engine Control Module (J623) ] Service and Repair.
- Move the lock carrier into the service position. Procedures
with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Remove the clutch master cylinder supply hose - 2 - from the brake fluid reservoir - 4 -.
- Seal the supply hose - 2 - using the sealing tool (T10249) - 1 - or a plug from the engine bung set (VAS 6122).
- Secure the supply hose - 2 - out of the way.
- Pull out the clip - arrow - for the hose/line assembly - A - to the stop.
- Pull the hose/line assembly - A - out of the breather assembly and seal it off.
Do not operate the clutch pedal any more.
with a Direct Shift Gearbox (DSG(R))
- Remove the selector lever cable from the transmission.
Continuation for All
- Remove the nut and ground wire - arrow - from the longitudinal member.
- Disconnect the connector - 2 -.
- Remove the fan shroud upper bolts - arrows -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the connector - arrow - and free up the wire.
Risk of scalding due to hot steam and hot coolant:
• The coolant system is under pressure when the engine is warm.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the coolant expansion tank cap.
- Loosen the drive axle bolts.
- Remove both front wheels.
- Remove the noise insulation..
- 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 connector - 1 - and remove the fan shroud lower bolts - arrows -.
- Remove the fan shroud downward.
- Disconnect the connector - 2 - from the engine coolant temperature sensor on radiator outlet.
• Store drained coolant in a clean container for disposal or to be reused again later.
- Place the drip tray for VAS 6100 (VAS 6208) under the engine.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Service and Repair.
- Disconnect the coolant hoses - 1 and 2 -.
The fuel system is under pressure!
• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect the fuel supply line - 1 - and the vent line - 2 -.
- Seal the lines so that the fuel system is not contaminated by dirt, etc.
- Remove the upper coolant hose - arrow - from the radiator.
- Remove the coolant hoses - arrows - from the heater core.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the drive axles.
- From the top, remove the front exhaust pipe to exhaust manifold/turbocharger nuts - arrows -
- 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.
Risk of injury from refrigerant:
• Do not open the A/C refrigerant circuit.
- Remove the A/C compressor bolts - arrows -.
Danger of causing damage to the refrigerant lines:
• Do not stretch, kink or bend the refrigerant lines and hoses.
- Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.
- Remove the after run coolant pump bracket bolt - 2 -.
• The after run coolant pump stays in the installed position.
- Remove the pendulum support bolt - 1 -.
- Then, remove the pendulum support bolts - 2 and 3 - and remove the pendulum support.
- Disconnect the vacuum hoses - arrows -.
- Disconnect all remaining electrical wires from the engine and transmission, as necessary and set them aside.
- Disconnect all coolant, vacuum and intake hoses connections from the engine.
• Install the pin (T10359/2) to the engine support (T10359) and mount the tensioner from the transmission set.
- Install the engine support (T10359) - 1 - to the engine and guide it onto the mount.
- Seat the tensioner - 3 - in order to prevent the engine from tilting out of the engine support (T10359).
- Secure the engine support (T10359) - 1 - to the cylinder block using the bolt - 3 - and tighten it to approximately 20 Nm.
• The threaded hole for the bolt - 3 - serves to secure the after run coolant pump.
- Install the engine-/gearbox jack (V.A.G 1383 A) to the engine support (T10359).
- Slightly tension the engine and transmission subassembly.
• Use the step ladder (VAS 5085) to remove the engine and transmission mount to bracket bolts.
- Remove the engine mount to engine mount bracket bolts - arrows -.
with a Manual Transmission
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
with a DSG(R)
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
Continuation for All
• Verify that all hose and wire connections between the engine, transmission and body have been disconnected.
• The engine and transmission subassembly must be guided with care to prevent damage while lowering.
with a DSG(R)
- Pay attention to the selector lever cable.
Continuation for All
- Pull the engine and transmission as far as possible to the left front and slowly lower it.
Secure the engine to the engine and transmission holder (VAS 6095) whenever working on it. Refer to => [ Engine, Securing to the ] Procedures.