Engine, Removing

Special tools and workshop equipment required 

• Pry Lever: 80-200 
• Engine Sling - Engine Bracket: 2024A /1  for the Engine Sling: 2024A 
• Securing element from the Transmission Support: 3282 
• Engine Bung Set: VAS6122 
• Coolant Collecting System: VAS5014  or Shop Crane - Drip Tray: VAS6208 
• Hose Clip Pliers: VAS6362 
• Engine and Gearbox Jack: VAS6931 
• Support Bridge: T10323 
• Engine/Gearbox Jack - Engine Support: T10359A 
• Commercially available Step Ladder
• Protective Eyewear
• Safety Gloves

Procedure 

• The engine with transmission is removed downward.
• During installation, all cable ties must be installed at the same location.

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

Vehicles with Secondary Air System: 

Remove the left front wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

Continuation for all vehicles: 

-- Loosen the clamps -1 and 2- and remove the air duct hose.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set: VAS6122  .

-- Disconnect the connector -1-.

-- Place the Coolant Collection System: VAS5014  or Shop Crane - Drip Tray: VAS6208  underneath.

-- Lift the clamp -3- and remove the lower right coolant hose from the radiator and drain the coolant.

Vehicles with Dual-Clutch Transmission: 

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-- Loosen the coolant hose -arrow-, remove the coolant hose and hold it toward the rear and let the coolant drain.

Continuation for all vehicles: 

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the bolts -1 and 3-.

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-- Release the catch -arrow- and remove the cover -2-.

-- Free up the coolant hose -2-.

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-- Open the catches -arrows- and remove the upper air duct -1-.

Vehicles with Secondary Air System: 

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-- Press the release buttons on both sides and remove the secondary air system hose -2-.

Continuation for all vehicles: 

-- Carefully remove the vacuum hose -1- at the same time to not damage it.

-- Loosen the hose clamp -3- and remove the air duct hose.

-- Remove the air filter housing -4- upward from the bracket.

-- Remove the bolt -arrow- on the left and right.

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-- Unclip and remove the lower section -1- of the air duct.

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Disconnect the vacuum hose -2- at the same time to not damage it.

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-- Press the release button on the vacuum hose -1- and remove the hose from the vacuum pump.

-- Place a cloth underneath to catch any escaping coolant.

-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

-- Hold the coolant hoses downward and allow the coolant to drain.

-- Remove the connector -1- from the bracket and disconnect them, and then free up the wire.

Vehicles with a particulate filter: 

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-- Remove the bolt -arrow- for the pressure lines.

-- Free up the pressure lines.

Continuation for all vehicles: 

-- Remove the bolt -2- and the screw-type clamp.

-- Remove the nuts -1 and 3- and tie up the catalytic converter to the rear (shown with the engine removed).

Vehicles with a particulate filter: 

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-- Remove the bolts -arrows- and nut -1- and remove the heat shield -2-.

-- Disconnect the connector -2-.

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-- Remove the bolts -arrows- and move the pressure lines with the Exhaust Pressure Sensor 1 -G450- toward the rear.

Continuation for all vehicles: 

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-- Place a cloth under the separating point to catch any escaping fuel.

-- Disconnect the fuel line -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Free up the fuel line.

-- Push the release buttons on both sides of the EVAP canister hose -2-.

-- Remove and free up the hose.

Vehicles with Fuel Tank Leak Detection Module -GX36- 

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-- Remove the bolt -arrow- and remove the EVAP system hose.

Continuation for all vehicles: 

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-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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

• Use the Pry Lever: 80 - 200  for removing the spiral clips in the following steps.
  Fig 8: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -1- from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

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-- Remove the connectors -2 and 3- from the bracket and disconnect them and then free up the wires.

Vehicles with Dual-Clutch Transmission: 

-- Remove the nut -4- and free up the ground wire.

Continuation for all vehicles: 

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-- Release the retainers -arrows- and remove the cover -1- from the engine compartment E-box.

-- Open the retainers with a screwdriver -arrow-, remove the cover -1- for the engine compartment E-box upward.

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-- Remove the nut -arrow- and free up the wire.

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-- Disconnect the connector -1- by sliding the retainer toward the rear and pressing the release downward.

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-- Push the B+ terminal protector -2- back and disconnect the B+ wire from the starter solenoid switch.

-- Loosen the bolts -arrows- for the transmission mount approximately two turns.

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-- Loosen the bolts -arrows- for the engine mount approximately two turns.

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-- Loosen the hose clamp -1-, remove the air duct hose from the charge air cooler.

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-- Disconnect the connector -1- for the radiator fan, to do this push the clip in the direction of -arrow A- and push the retainer downward.

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-- Push the left and right locking latches for the fan shroud at the same time -arrow B- and remove the fan shroud upward from the radiator and remove from underneath.

-- Loosen the hose clamp -2-.

-- Free up the coolant hose -3-.

-- Remove the screws -arrows-.

-- Disconnect the connector -1- from the Charge Air Pressure Sensor -G31-.

-- Remove the right air duct pipe.

-- Remove the left and right drive axle from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the drive axles to the rear.

TIP:

Be careful not to damage the protective coating on the drive axle.

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

-- Remove the ribbed belt from the A/C compressor belt pulley and release the tension on the tensioner.

-- Remove the A/C compressor from the bracket with the refrigerant lines still attached and tie up to the right. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

Vehicles with a particulate filter: 

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-- Remove the nuts -arrows-, free up the bracket -1- for the pressure line and push it to the side.

Vehicles with Dual-Clutch Transmission: 

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-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to the appropriate Service Information .

-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743- by turning the twist lock counter-clockwise -arrow-.

-- Equipped on some models: disconnect the connector -arrow- for the differential lock.

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Vehicles with Automatic Transmission 

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-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to the appropriate Service Information .

-- Disconnect the connector -2-.

-- Remove the hose -1- and free up the ground wire.

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-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Disconnect the connector -2-.

-- Remove the bolt -1- and disconnect the ATF lines.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set: VAS6122  .

Vehicles with Secondary Air System: 

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-- Disconnect the secondary air hose -arrow- by pressing the release buttons on both sides.

Continuation for all vehicles: 

-- Remove the nuts -arrows- and remove the right drive axle heat shield -1-.

-- Remove the bolts -arrows- and remove the heat shield -1-.

-- Mark the position of flexible disc and the bevel box flange to each other for reinstallation.

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-- Using a lever to counterhold the triangular flange, remove the driveshaft from the bevel box -arrows-.

-- Secure the Support Bridge: T10323  with a bolt in the inside rear threaded hole for the subframe.

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TIP:

A subframe bolt is suitable for this.

-- Place a cloth -A- on the Support Bridge: T10323  .

-- Remove the driveshaft from the bevel box.

-- Remove bolt -arrow- and push the bracket for the wiring harness to the side.

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-- Fasten the Adapter: T10359/3  on the Engine/Gearbox Jack - Engine Support: T10359A  as shown.

-- Tighten the Pin: T10359/2  onto the engine bracket with the securing element -A- from the Transmission Support: 3282  .

-- Place the Engine/Gearbox Jack - Engine Support: T10359  in the Engine and Gearbox Jack: VAS6931  .

-- Fasten the Engine/Gearbox Jack - Engine Support: T10359A  on the cylinder block with the bolt -1- to 20 Nm and secure it with the securing element -2- from the Transmission Support: 3282  .

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-- Place the Engine and Gearbox Jack: VAS6931  on the Engine/Gearbox Jack - Engine Support: T10359A  and raise the engine/transmission assembly slightly.

TIP:

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Use a step ladder to remove the assembly mount bolts.

-- Completely remove the engine mount bolts -arrows-.

-- Completely remove the transmission mount bolts -arrows- completely.

-- Carefully drain the engine/transmission assembly while doing so check is all vacuum lines or wires between the engine, transmission and body are separated.