Engine, Removing

Special tools and workshop equipment required

Pry Lever - Rmv Outside Mirror 80 - 200
Engine/Transmission Jack V.A.G 1383 A
Step Ladder VAS 5085
Drip Tray VAS 6208
Hose Clip Pliers VAS 6362
Bracket 2024 A /1, part of the Engine Sling 2024 A
Locking Pin T10060 A
Engine/Trans. Support T10012
Protective eyewear
Protective gloves

Procedure

NOTE:

The engine is removed downward together with the transmission.

During installation, cable ties must be installed at the same location.

During installation, the heat shield boots must be installed at the same location.

WARNING:

Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
To reduce pressure, cover coolant reservoir cap with cloth and carefully open.

-- Open coolant reservoir cap.

Fig 1: Coolant Level Markings

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-- Remove the engine cover -arrows-.

Fig 2: Identifying Engine Cover

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-- Remove the cover for the air guide; to do so disengage the side clips -arrows-.

Fig 3: Identifying Air Duct Cover Slide Clips

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-- Release the left and right spring clips -arrow A- and disconnect the lower air guide -2-.

Fig 4: Unclipping Lower Air Guide By Releasing Left And Right Retainers -Arrow A-.

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-- Move the lower air guide slightly to the rear and disengage the lower air guide -3-.

-- Disengage the air guide pipe -1- from the lower air guide -arrow B-.

-- Disconnect electrical connector -2- on mass air flow sensor -G70-.

Fig 5: Removing Air Filter Housing

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-- Disconnect the hose -1-.

-- Remove the coolant hose by loosening the hose clamp -3-.

-- Remove the bolt -4- and air filter housing.

-- Remove the bolts -arrows- and the air guide from the lock carrier.

Fig 6: Identifying Air Guide Screws -Arrows- And Air Guide

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-- Remove the screws -upper arrows- on the fan shroud.

Fig 7: Identifying Coolant Fan Control Module J293 And Screws

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NOTE:

The screws -lower arrows- will be removed later.

Ignore -1-.

-- Remove both front wheels.

-- Remove the noise insulation -1-. Refer to Removal and Installation .

Fig 8: Identifying Noise Insulation

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-- Cabrio: Remove the noise insulation frame -arrow-. Refer to Removal and Installation .

Fig 9: Identifying Noise Insulation Frame

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-- Remove the front section of the left and right front wheel housing liners. Refer to Removal and Installation .

Fig 10: Identifying Front Section Of Left Front Wheel Housing Liner

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-- Loosen the hose clamp -2-, lift the retaining clamp -1- and remove the air guide hose.

Fig 11: Identifying Air Cooler Air Duct And Clamps

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-- Loosen the hose clamp -2-, lift the retaining clamp -1- and remove the air guide hose.

Fig 12: Identifying Clamp -2- And Circlip -1-

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-- Seal the open lines and connections with clean plugs from the engine bung set VAS 6122.

-- Disconnect the connector -1-.

Fig 13: Identifying Coolant Fan Control Module J293 And Screws

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-- Remove the bolts -lower arrows- and remove the fan shroud downward.

NOTE:

Collect escaping coolant in a clean container for disposal or reuse.

-- Place VAS 6208 under engine.

-- Lift the clamp to remove the right lower coolant hose -arrow- and let the coolant drain.

Fig 14: Identifying Coolant Hose Quick Acting Coupling

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-- Loosen the hose clamp -arrow-, drain the coolant and remove the lower coolant hose for the EGR cooler pump -V400-.

Fig 15: Identifying Hose Clamp

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-- Remove the bolts -lower arrows- on the back of the radiator.

Fig 16: Identifying Radiator Bolts

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NOTE:

The bolts -upper arrows- will be removed later.

-- Loosen the hose clamp -arrow-, drain any remaining coolant and remove the additional coolant hose from the engine oil cooler.

Fig 17: Identifying Hose Clamp

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-- Remove the battery. Refer to REMOVAL AND INSTALLATION .

Fig 18: Identifying Screws And Securing Bracket For Battery

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-- Remove the bolts -arrows- and remove the battery tray -1-.

Fig 19: Identifying Battery Tray And Bolts

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-- Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Fig 20: Identifying Air Guide Pipe

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-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Loosen the hose clamp -2- and remove the air guide pipe.

-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

Fig 21: Identifying Turbocharger Vacuum Diaphragm

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-- Disconnect the vacuum hose -3-.

NOTE:

Ignore -1-.

-- Disconnect the vacuum hose -arrow- from the brake booster.

Fig 22: Identifying Vacuum Hose

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NOTE:

Lay a cloth under the heat exchanger to catch escaping coolant.

Fig 23: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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-- Lift the clamps -arrows- and remove the heat exchanger.

-- Disconnect the connectors -3- from the bracket.

Fig 24: Installed Locations and Connectors

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-- Free up the wires -2-3-4-5-.

NOTE:

Ignore -1-.

-- Remove the clamp -2-.

Fig 25: Identifying Exhaust Gas Temperature Sensor 2 -1-.

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NOTE:

Ignore -1 and 3-.

-- Disconnect the connector -2- on exhaust pressure sensor 1 -G450-.

Fig 26: Identifying Pressure Sensor And Connector

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-- Remove the bolt -3- and pull exhaust pressure sensor 1 of its mount -arrow-.

-- Remove the bolt -1- at the top of the particulate filter mount.

NOTE:

The installed position may differ depending on the date of manufacture.

-- Remove the differential pressure sensor -3- from the cylinder head cover.

Fig 27: Exhaust Pressure Sensor 1 -G450- -3-

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-- Disconnect the connector -4- on the fuel temperature sensor -G81-.

Fig 28: Locating Fuel Temperature Sensor

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WARNING:

Very hot fuel can burn your skin.

The temperature of the fuel lines and may reach 100 °C (212 °F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear protective gloves.
Wear safety glasses.

-- Loosen the hose clamps -2- and -3- and remove the fuel supply and return hoses.

-- Seal the open lines and connections with clean plugs from the engine bung set VAS 6122.

NOTE:

Ignore -1- and -arrow-.

-- Remove the coolant hose; do to so, loosen the hose clamp -1-.

Fig 29: Identifying Coolant Hose

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NOTE:

Ignore -2- and -arrows-.

-- Remove bolt -1-.

Fig 30: Identifying Windshield Wiper Fluid Reservoir Filler Tube -2- And Bolt

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-- Move the filler tube and windshield wiper fluid reservoir filler tube -2- to the side.

NOTE:

Ignore -3-.

The installation location is shown with the fuel filter removed.

-- Disengage the fuel hose -2- from the bracket.

Fig 31: Identifying Fuel Hose & Lines

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-- Removed the bracket for the fuel lines -arrow- and move it to the side.

-- Disconnect the connector -1- on the auxiliary fuel pump -V393-.

-- Remove the bolts -3- then remove the bracket and the auxiliary fuel pump and move them to the side.

-- Loosen the hose clamp -1-, free up the coolant hose and remove the coolant hose from the coolant reservoir.

Fig 32: Identifying Fuel Supply Line, Fuel Return Line & Coolant Hose

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NOTE:

Ignore -2 and 3-.

-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

Fig 33: Identifying Left Upper Coolant Hose Clamp

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-- Disconnect the connector -A- on the high pressure sensor -G65- -B-.

Fig 34: Disconnecting Connector -A- On High Pressure Sensor -G65- -B-

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NOTE:

Ignore -C-.

-- Remove the bolts -upper arrows- on the back of the radiator and then remove the radiator.

Fig 35: Identifying Radiator Bolts

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-- Remove the windshield wiper arms. Refer to REMOVAL AND INSTALLATION .

Fig 36: Removing Windshield Wiper Arm With Puller T10369/1

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-- Unclip the spray nozzles -arrow-.

Fig 37: Removing Spray Nozzle

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-- Slide the spray nozzles with the lines connected through the assembly opening in the plenum chamber.

-- Remove gasket -1-.

Fig 38: Identifying Plenum Chamber Cover And Rubber Seal

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CAUTION:

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 the plenum chamber cover.

NOTE:

Use the 80 - 200 for removing the spiral clips in the following procedure.

Fig 39: Free Electrical Wiring Up To Generator Using 80-200

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-- Free up the rear engine wiring harness on the plenum chamber bulkhead.

-- Remove the bolts -arrows- and remove the plenum chamber bulkhead.

Fig 40: Identifying Plenum Chamber Bulkhead And Bolts

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-- Remove engine control module ECM. Refer to Removal and Installation .

-- Disconnect the engine wiring harness electrical connector -1-.

Fig 41: Identifying ECM And Engine Wiring Harness Electrical Connector

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NOTE:

Ignore -2-.

-- Release pass-through -arrow- for engine wiring harness and pull off upward.

Fig 42: Release Pass-Through -Arrow- For Engine Wiring Harness

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-- Open wiring router bracket -arrows-.

Fig 43: Opening Wiring Router Bracket

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-- Push the wheel housing liner slightly to the side, release the retainers on the back side -arrows- and remove the connector -1- with the bracket.

Fig 44: Identifying Wiring Router Connector

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-- Disconnect the connector from the bracket.

-- Disconnect the connectors -1- and free them up.

Fig 45: Identifying Electrical Connector -1- And Wiring Guide Bracket -2-

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-- Open the underlying wiring guide bracket -2-.

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

-- Disconnect the electrical connector -arrow- on the lower left longitudinal member.

Fig 46: Identifying Lower Left Longitudinal Member Electrical Connector

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NOTE:

The illustration shows the installation location from below.

-- Remove E-box cover by slide both latches in direction of -arrow-.

Fig 47: Identifying E-Box Cover And Latches

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-- Remove the nut -arrow- and then remove and free up the terminal 30 wire from the engine compartment E-box.

Fig 48: Locating Engine Compartment E-Box Nut

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Manual Transmission

-- Disconnect the connector -1-.

Fig 49: Identifying Engine Compartment E-Box Connector

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NOTE:

Ignore -arrows-.

-- Cut off cable ties -arrow- for protective boot -3-.

Fig 50: Identifying Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

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-- Disconnect the connector -2-.

-- Fold back protective boot and remove B+ wire from starter solenoid.

-- Remove the ground wire nut -1-.

-- Remove upper starter bolt.

-- Remove the shift cable lock washer -3- from the transmission shift lever -1- and then remove the cable from the ball -arrow-.

Fig 51: Identifying Shift Cable Lock Washer To Transmission Shift Lever, Cable And Pins

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Metal Shift Relay Lever

-- Remove the selector cable lock washer -4- from the shift relay lever -2- and then remove the cable from the ball -arrow-.

Plastic Shift Relay Lever

The cable retainer must be disconnected from the selector lever cable prior to removal to prevent damaging the cable.

-- Pull the safety mechanism all the way to the front -arrow 1- and then lock it to the left -arrow 2-.

Fig 52: Disconnecting Cable Retainer From Selector Cable

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-- Push the selector relay lever forward -arrow 3-.

Continuation for Vehicles with a Manual Transmission

Fig 53: Identifying Cable Mounting Bracket From Transmission

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-- Remove the cable mounting bracket from the transmission -arrows- and move it to the side with the cables.

-- Vehicles with a plastic hose between the clutch master cylinder and the clutch slave cylinder: clamp off the supply hose on the brake fluid reservoir with 3094.

Fig 54: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

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-- Vehicles with a hose/line assembly between the clutch master cylinder and the clutch slave cylinder: clamp off the hose -A- on the hose/line assembly with 3094.

Fig 55: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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NOTE:

Disregard -arrow-.

NOTE:

Make sure no brake fluid gets onto the starter or on the transmission. If this happens, clean it off thoroughly.

Fig 56: Identifying Hose/Line Assembly -A-, Ground (GND) Cable -B-

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-- Pull the clamp -arrow- all the way until it stops.

-- Remove the plastic hose or the hose/line assembly -A- from the bleeder/clutch slave cylinder.

NOTE:

Ignore -B-.

-- Seal the open lines and connections with clean plugs from the engine bung set VAS 6122.

Vehicles with Dual Clutch Transmission

-- Cut off cable ties -arrow- for protective boot -1-.

Fig 57: Identifying Control Module Connectors

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-- Disconnect the connector -2-.

-- Fold back protective boot and remove B+ wire from starter solenoid.

-- Remove the nut -3- and remove the ground wire.

CAUTION:

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.

-- Disconnect the connector -1-.

Fig 58: Identifying Wiring Harnesses And Connector On Hot Side Charge Air Pipe

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NOTE:

Ignore -arrows-.

All Vehicles

-- Remove the subframe bolts -arrows- on the engine side 2 turns.

Fig 59: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Remove the subframe bolts -arrows- on the transmission side 2 turns.

Fig 60: Identifying Engine Mount To Engine Mount Bracket Bolts

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Vehicles with Air Conditioning

CAUTION:

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.

-- Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.

Fig 61: Pivoting Tensioner Clockwise And Securing Tensioning Element With T10060 A

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-- Secure the tensioning element with T10060 A.

-- Remove ribbed belt.

-- Disconnect the connector -2- on the A/C compressor regulator valve -N280-.

Fig 62: Identifying A/C Compressor Bolts

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CAUTION:

There is a risk of damaging the condenser, the A/C compressor and the refrigerant lines and hoses.

Do not stretch, kink or bend coolant lines and hoses.

-- Remove the bolts -arrows-. Then remove the A/C compressor -1- with the refrigerant pipes still connected and tie them up.

All Vehicles:

-- Disconnect electrical connector -1- on oil level thermal sensor -G266-.

Fig 63: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.

Vehicles with Front Wheel Drive

-- Remove the bolts -arrows- and remove the right drive axle heat shield.

Fig 64: Identifying Protective Cap For Drive Axle On Engine

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-- Remove the left and right drive axles from the transmission flange shaft.

-- Tie up the left drive axle.

-- Remove the left and right coupling rod nuts -arrow- on the stabilizer bar.

Fig 65: Identifying Left And Right Coupling Rod Nuts

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Vehicles with All Wheel Drive

-- Remove the bolts -arrows- and remove the right drive axle heat shield.

Fig 66: Identifying Right Drive Axle Heat Shield

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-- Remove the left drive axle from the transmission flange shaft and tie it up.

NOTE:

Make sure the drive axle surface protection is not damaged.

-- Remove the right drive axle from the bevel box flange shaft.

All Vehicles

-- Remove bolts -1 to 3- and remove pendulum support.

Fig 67: Identifying Pendulum Support & Bolts

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-- Mark the position of the ball joint nuts -arrows-.

Fig 68: Identifying Ball Joint Lower Nuts

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-- Remove the nuts on the right ball joint.

-- Remove the nuts on the left front level control system sensor -G78- bracket, if equipped.

-- Disengage the control arm from the transverse link.

Vehicles with Front Wheel Drive

-- Tilt the right drive axle forward while pressing the engine/transmission subassembly forward.

-- Secure the drive axle to the longitudinal member -arrow-.

Fig 69: Identifying Drive Axle Secured To Longitudinal Member

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NOTE:

Make sure the drive axle surface protection is not damaged.

Vehicles with All Wheel Drive

-- Tilt the right suspension strut outward and support it with the extension 2024 A /1 as shown in the illustration.

Fig 70: Tilting Right Suspension Strut Outward And Supporting It With Extension 2024 A /1

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WARNING:

Loose support components could cause an accident.

Secure the securing pin and control arm using the securing pin -arrow- and nut -1-.

NOTE:

The installed position of the left front suspension is shown in the illustration.

-- Position of flexible disc and bevel box flange are marked to each other.

-- Remove driveshaft flexible disc from bevel box -arrows- while counterholding on triangle flange with lever.

Fig 71: Identifying Driveshaft Flexible Disc

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-- Press the engine/transmission subassembly slightly forward and remove the driveshaft from the bevel box.

CAUTION:

Risk of damaging sealing ring -arrow- in driveshaft flange.

Press driveshaft horizontally as far back and to right side of vehicle as possible.

Fig 72: Identifying Sealing Ring In Driveshaft Flange

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NOTE:

If seal is damaged, driveshaft must be replaced.

-- Remove the nuts -1- and -2- and the particulate filter mount.

Fig 73: Identifying Particulate Filter Mount And Nuts

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-- Remove the bolts -1- on the cable mounting bracket.

Fig 74: Identifying Elector Lever Cable Bracket Bolts And Locking Washer

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-- Remove locking washer -3- -arrow- and remove selector lever cable from transmission.

NOTE:

Ignore -2-.

-- Remove bolts -arrows-.

Fig 75: Identifying Charge Air Pipe Bolts

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-- Free up the coolant hose -3-.

-- Loosen the hose clamp -2-.

-- Disconnect the connector -1- on the charge air pressure sensor -G31- and then remove the air guide pipe.

-- Remove the bolt -arrow- and move the EGR cooler pump -V400- to the side.

Fig 76: Identifying Engine Coolant Circulation Pump Bolt

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NOTE:

Ignore -1, 2 and 3-.

-- Loosen the fasteners -arrows- and remove the oil pan noise insulation -1-.

Fig 77: Identifying Oil Pan Noise Insulation -1-

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-- Attach the T10012 to cylinder block with bolt -1- and nut -2-. Tighten to approximately 20 Nm.

Fig 78: Attaching Engine Support T10012 On Engine

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-- Place V.A.G 1383 A on T10012 and raise engine/transmission subassembly slightly.

NOTE:

Use VAS 5085 to remove bolts for assembly mounting.

Fig 79: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Remove the subframe bolts -arrows- on the engine side.

-- Remove the subframe bolts -arrows- on the transmission side completely.

Fig 80: Identifying Engine Mount To Engine Mount Bracket Bolts

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NOTE:

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

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

Make sure there is enough clearance for the A/C compressor and for the left drive axle.

-- Lower the engine/transmission subassembly a little.

-- Move the engine/transmission subassembly forward and lower it a little more.