Part 1

Engine, Removing

Special tools, testers and auxiliary items 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

• 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.

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.

- Remove the engine cover - arrows -.

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

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

- 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).

- 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.

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

• The screws - lower arrows - will be removed later.

• Ignore - 1 -.

- Remove both front wheels.

- Remove the noise insulation - 1 -.

- Cabrio: Remove the noise insulation frame - arrow -.

- Remove the front section of the left and right front wheel housing liners.

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

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

- Disconnect the connector - 1 -.

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

• 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.

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

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

• 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.

- Remove the battery.

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

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

- 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.

- Disconnect the vacuum hose - 3 -.

• Ignore - 1 -.

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

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

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

- Disconnect the connectors - 3 - from the bracket.

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

• Ignore - 1 -.

- Remove the clamp - 2 -.

• Ignore - 1 and 3 -.

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

- 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.

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

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

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

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).

• Ignore - 1 - and - arrow -.

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

• Ignore - 2 - and - arrows -.

- Remove bolt - 1 -.

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

• Ignore - 3 -.

• The installation location is shown with the fuel filter removed.

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

- 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.

• Ignore - 2 and 3 -.

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

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

• Ignore - C -.

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

- Remove the windshield wiper arms.

- Unclip the spray nozzles - arrow -.

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

- Remove gasket - 1 -.

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.

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

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

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

- Remove engine control module ECM.

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

• Ignore - 2 -.

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

- Open wiring router bracket - arrows -.

- 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.

- Disconnect the connector from the bracket.

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

- Open the underlying wiring guide bracket - 2 -.

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