Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Drip tray (VAS 6208)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Engine/Trans. Support (T10012)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Ring Spanner 7-Piece Set (3337)
• Engine Bung Set (VAS 6122)
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• Heat insulation sleeves removed during engine removal should be reinstalled in the same location when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
Observe procedures for disconnecting battery.
- Remove luggage compartment floor covering.
- Release retaining clips - arrows - and remove negative post cover.
• If the battery negative terminal cover is under the rear cross panel trim, trim must be removed.
- With ignition switched off, disconnect battery ground (GND) cable - arrow -.
Cover cap of expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- Remove center noise insulation fasteners - 1 to 4 -.
- Remove noise insulation at left and right - arrows -.
- Remove noise insulation frame - arrow -.
- Disconnect the electrical connector on the Mass Airflow (MAF) Sensor (G70) - 3 -.
- Open clips - 1 and 2 - and remove air guide hose from MAF sensor.
- Remove front air intake connector on lock carrier - 4 -.
- Remove engine cover.
- Remove air guide hose - arrow - with the (V.A.G 1921).
- Remove electrical connector - arrow - for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.
- Remove the heated oxygen sensor (HO2S) (G39) - arrow - using a tool from the (3337).
- Pry off the caps on the wiper arms with a screwdriver and remove the nuts.
- Pull off and remove wiper arms from wiper axles.
- Remove rubber seal - 1 - for plenum chamber cover.
- Remove the plenum chamber cover - 2 -.
- Free up engine wiring harness in plenum chamber.
- Remove the engine control module.
- Separate the electrical connector - 1 - for engine wiring harness.
- Release pass-through for engine wiring harness - arrow - and pull off upward.
- Open bracket of wiring - arrows -.
- Free up and disconnect the electrical connector - 1 -.
- Open the underlying wiring guide bracket - 2 -.
- Open the wiring guide bracket - 3 -.
- Remove engine wiring harness to control module from wiring.
• To unclip spiral clip, use the (80 - 200).
- Disconnect the connector - 1 - from the back-up lamp switch.
- Remove ground (GND) cable - 2 -.
- Separate electrical connector - 3 -.
- Push cover - 4 - toward rear.
- Remove wiring - arrow - on starter and free it up.
- Press both latches in direction of - arrow - and remove engine compartment E-box cover.
- Remove the electrical harness - 1 - and free up the wiring to the engine.
- Disconnect the electrical connector - 2 -.
- Remove the bolts - 1 - from above.
- Place the (VAS 6208) under engine.
- Drain the coolant, by pulling off the lower coolant hose - arrows -.
- Remove the air duct - 1 and 2 - for charge air cooler.
- Disconnect the connector - 2 -.
- Remove bolts - 3 - and remove the fan shroud downward and off.
- Disconnect upper coolant hose from radiator - arrow -.
- Disconnect coolant hoses to heat exchanger - arrows -.
- Remove the accessible nuts - arrows - for the front exhaust pipe/turbocharger from above.
• The illustration depicts the engine removed from behind.
- Disconnect vacuum hose - arrow - from brake booster.
- Unclip the lock washers - 1 - and - 2 - at both cables.
- Pull off the cable retainers from transmission selector lever and relay lever.
- Remove cable mounting bracket from transmission and lay aside - arrows -.
Do not operate the clutch pedal anymore after hose for slave cylinder has been disconnected.
- Pull out clip - 2 - to the stop in direction of - arrow - and pull off hose line - 1 -.
The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.
- Mark the fuel line - 2 - and the EVAP line - 1 -.
- Disconnect the fuel line - 2 - and lay it free.
- Disconnect the EVAP line - 1 - and lay it free.
- Disconnect the vacuum line - 3 - to EVAP canister (press release buttons).
- Remove EVAP canister upward.
- Disconnect coolant hoses - 1 and 2 -.
- Discharge the air conditioning system.
- Remove refrigerant lines - arrow - at the compressor.
- Seal off openings with sealing plugs from (VAS 6122).
- Unscrew the bolts - arrows - of the engine mountings approximately 2 turns.
- Unscrew the bolts - arrows - of the transmission mountings approximately 2 turns.
- Disconnect electrical connector - arrow -.
- Remove air duct - arrows -.
- Disconnect electrical connector - 1 - from high pressure sensor (G65).
- Disconnect refrigerant line from condenser - 2 -.
- Disconnect the electrical connector on the oil level sensor - 1 -.
- Unclip the retainer - 2 -.
- Remove the right drive axle heat shield - arrows -.
- Remove the left and right drive axles.
- Remove nuts - 1 - and - 2 - on oxygen sensor electrical connector bracket under vehicle floor and remove cover.
- Remove bolt - 3 - and free up electrical wiring to oxygen sensor.
- Remove connector coupling from bracket - arrow -.
- Disconnect electrical connector to oxygen sensor (O2S) after three way catalytic converter (TWC) (G130).
- Remove the remaining nuts - arrows - for the front exhaust pipe/turbocharger from below.
- Remove exhaust system bracket and tunnel brace - arrows -.
• Do not bend the flex joint in the front exhaust pipe more than 10° or it could be damaged.
- Disconnect the exhaust system at the clamping sleeve - arrows -.
- Remove front exhaust pipe with catalytic converter and front muffler.
- Remove bolts - 1 - 3 - and remove pendulum support.
- Remove auxiliary coolant pump bolts - arrows -.
- Attach the (T10012) to the cylinder block using the bolt - 1 - and nut - 2 - and tighten to approximately 20 Nm.
- Insert the (V.A.G 1383 A) into the (T10012) and lift slightly.
• Use the (VAS 5085) to remove bolts for assembly mounting.
- Remove bolts - arrows - at engine assembly mounting.
- Remove bolts - arrows - at transmission assembly mounting.
• 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.
- Pull engine/transmission assembly as far forward as possible and slowly lower it.