Removing
Engine, removing
Note:
^ The engine is removed from underneath 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 the engine.
^ Secure all hose connections with hose clamps of the same type as those installed at the factory.
^ V.A.G 1921 hose clip pliers are recommended when installing spring-type clips.
^ Make sure the connectors are correctly assigned; mark if necessary.
- Obtain radio anti-theft code on vehicles with coded radio.
- With the ignition switched off, disconnect the battery Ground strap.
- Remove engine cover from cylinder head cover.
- Remove cover in front of intake manifold.
- Disconnect air duct at bottom of right side longitudinal member (air duct leads to charge air cooler).
- Remove sound insulation in the center and on left and right sides (arrows).
- Unbolt heat shield for right side drive axle.
- Unbolt pendulum support.
- Unbolt left and right side drive axles from transmission flange.
- Move left side drive axle toward rear of vehicle and secure in place by tying to stabilizer bar.
- Remove front exhaust pipe.
Note:
Do not bend the flexible connection on the front exhaust pipe more than necessary (not more than 10 degrees).
- Secure support rails 457/1 to subframe with bolt M8 x 25 (-B-). Also secure engine support device 3300A (-C-) to support rails 457/1 (arrows).
- Press engine forward.
Note:
Make sure not to damage the power steering line.
- Loosen right side 12-point nut for drive axle. When doing this, vehicle must be standing on its wheels.
- Unbolt wheel.
- Press out drive axle using special tool 3283.
Note:
Make sure there is enough clearance when pressing out the axle shaft.
- Remove drive axle.
- Place drip tray V.A.G 1306 below engine.
- Remove cap from coolant expansion tank.
- Turn drain screw (arrow) on radiator counter-clockwise. If necessary, fit drain hose to connection.
- Disconnect bottom coolant hose from oil cooler (arrow) and allow remaining coolant to drain.
- Disconnect air hose -4- from mass air flow sensor.
- Disconnect electrical connectors for mass air flow sensor -1-.
- Remove bolts -2- and -3- and take off air cleaner housing.
The air intake hose connection on the turbocharger is removed as follows:
- Disconnect vacuum hose -1- from air recirculation valve.
- Disconnect hose from pressure control valve for crankcase breather -2-.
- Disconnect electrical connector from Wastegate bypass regulator valve -N75- (-3-).
- Disconnect hose -4- from Wastegate bypass regulator valve -N75-.
- Disconnect hose -5- at bulkhead (hose leads from solenoid valve to turbocharger).
- Remove wastegate bypass regulator valve from air intake hose and place it to one side on engine.
- Disconnect hose between EVAP canister and turbocharger on bulkhead.
- Pull retainer off turbocharger connection and disconnect air intake hose.
- Remove battery.
- Remove battery platform (arrows).
- Unbolt Ground wire -1- on engine/transmission flange.
- Disconnect wires -3- and -4- from starter.
- Disconnect connector -2- and pull out of retainer.
- Disengage wires from retainer on starter and move wires to one side.
- Disconnect connector -1- for electrical change-over valve on underside of bracket.
- Unbolt bracket from intake manifold (-2- and -3-) and disengage dipstick tube -4-.
- Disconnect wire -1- from terminal 30/B+ on generator.
- Disconnect connector -2- from terminal D+.
- Remove cable clip -3-.
Vehicles with air conditioning
- Disconnect connector from a/c compressor.
All models
- Remove coolant hose -1- (complete).
- Disconnect wires/connectors as follows:
2 - Knock Sensor (KS) I -G61 -
3 - Engine speed sensor (RPM) -G28- (center, gray)
4 - Knock Sensor (KS) II -G66-
6 - Oil pressure switch -F1-
- Take Generator wire out of retainer.
- Disconnect vacuum pipe -5- from intake manifold.
- Disconnect connector -1- for Intake air temperature sensor -G42- and connector -4- for Throttle valve control module -J338- (under throttle valve control module).
- Disconnect air hose -2- from throttle valve control module.
- Disconnect vacuum hose -3- (for EVAP canister) from throttle valve control module.
- Disconnect connector from Camshaft Position (CMP) sensor -G40- (arrow).
- Disconnect vacuum pipe -1- from vacuum reservoir.
- Unbolt vacuum reservoir -2- and remove from bracket.
- Disconnect connectors -3- from injectors and unclip support bar from fuel rail at points -4- and -5-.
- Unbolt Ground wire -6- between ignition coils 1 and 2.
- Disconnect connectors -7- from ignition coils.
- Disconnect connector from Engine Coolant Temperature (ECT) sensor -G62- (on coolant hose flange on left of cylinder head).
- Disconnect connector from Speedometer sensor -G22- (on rear of transmission).
- Move lines and hoses clear.
- Disconnect the following coolant hoses:
^ On expansion tank (top and bottom)
^ On cylinder head (top hose leading to radiator)
^ On bulkhead (two hoses leading to heat exchanger for heater)
^ On left of engine block, below cylinder head (hose joined to connection in upper coolant hose leading to radiator)
^ On oil cooler (rear hose)
- Disengage wiring harness from retainers and place to one side.
- Mark threaded sections of both selector cables -1- with a permanent marker pen so that they can be installed in same positions later.
- Pull collar in direction of arrow -2- (toward ball joint) to compress spring, then turn collar clockwise (arrow -3-) to lock in position.
- Disengage both threaded sections.
- Unclip clutch slave cylinder hose from selector cable support bracket (arrow).
- Remove bolts (arrows), remove selector cable support bracket from transmission and place to one side.
- Remove clutch slave cylinder from transmission and place to one side.
Note:
^ Do not open the hydraulic system.
^ Do not depress the clutch.
- Disconnect electrical wire from Back-up light switch -F4-.
- Disengage wiring harness from retainers and place to one side.
- Disconnect fuel supply line -1- and fuel return line -2- at connection point by pressing release tabs.
Note:
Check the colors of the connectors when connecting the fuel supply and return lines.
WARNING
The fuel system is under pressure! Before opening the system place a cloth around the connection, then release pressure by carefully loosening the connection.
- Loosen ribbed belt by turning tensioning element in direction indicated (arrow).
Note:
Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing the belt, ensure it is correctly seated in the pulleys.
- Remove ribbed belt.
The tensioning element can be locked in position with a suitable punch (4.5 mm diameter, approx. 55 mm long). Connecting rod support 3090 can also be used.
- Remove connecting pipe between both left and right crossmembers.
Right crossmember.
- Remove connector at both starter and transmission.
- Remove B+ cable from starter.
- Remove power steering fluid cooling line from transmission.
- Remove cooling line retaining clip at lower left and remove coolant hose.
- Open hose clamp at lower left of radiator and completely remove cooling line.
- Remove pulley from power steering pump (counterhold with socket wrench).
- Place clean container under pump.
- Open spring clips -3- from intake hose and remove hose.
- Remove flexible hose -4-.
Note:
For vehicles with pressure switch, remove connector first and remove switch.
- Unbolt pump bolts -1- and -2- from bracket (4x).
- Remove connector and hoses at secondary air pump.
- Remove secondary air pump.
- Disconnect two coolant fan connectors on radiator cowl (bottom left).
- Remove cowl from radiator (4 bolts) together with both fans and remove by pulling downward.
Vehicles with air conditioning
CAUTION
The air conditioning refrigerant circuit must not be opened.
- Remove retainers for refrigerant hoses.
- Unbolt A/C compressor, lift clear together with refrigerant hoses (do not disconnect) and tie in place on hood lock.
- Loosen engine/transmission mounting (about two turns only) on engine side. Do not remove bolts completely.
- Loosen engine/transmission mounting (about two turns only) on transmission side. Do not remove bolts completely.
- Raise vehicle.
- Bolt engine bracket T10012 to cylinder block with securing nut and bolt (M10 x 25/8.8). Tighten to approx. 20 Nm.
- Install engine/transmission jack V.A.G 1383A to engine bracket and raise engine/transmission slightly.
- Unbolt engine/transmission mounting on engine side. (Use step ladder VAS 5085 or equivalent for access to engine compartment from above.)
- Unbolt engine/transmission mounting on transmission side.
- Carefully lower engine/transmission assembly.
Note:
^ Check to make sure that all connections between engine and body have been disconnected.
^ The engine/transmission assembly must be carefully guided by a second technician while it is being lowered so as to avoid damaging the body panels.
- Remove bolts -1- to -8- on engine/transmission flange.
- Separate engine from transmission.