Part 2
Engine, Removing - Continued
- Disconnect the electrical connector - arrow - on the lower left longitudinal member.
• The illustration shows the installation location from below.
- Remove E-box cover by slide both latches in direction of - arrow -.
- Remove the nut - arrow - and then remove and free up the terminal 30 wire from the engine compartment E-box.
Manual Transmission
- Disconnect the connector - 1 -.
• Ignore - arrows -.
- Cut off cable ties - arrow - for protective boot - 3 -.
- 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 -.
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 -.
- Push the selector relay lever forward - arrow 3 -.
Continuation for Vehicles with a Manual Transmission
- 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).
- 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).
• Disregard - arrow -.
• Make sure no brake fluid gets onto the starter or on the transmission. If this happens, clean it off thoroughly.
- 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.
• 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 -.
- Disconnect the connector - 2 -.
- Fold back protective boot and remove B+ wire from starter solenoid.
- Remove the nut - 3 - and remove the ground wire.
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 -.
• Ignore - arrows -.
All Vehicles
- Remove the subframe bolts - arrows - on the engine side 2 turns.
- Remove the subframe bolts - arrows - on the transmission side 2 turns.
Vehicles with Air Conditioning
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.
- Secure the tensioning element with (T10060 A).
- Remove ribbed belt.
- Disconnect the connector - 2 - on the A/C compressor regulator valve (N280).
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).
- 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.
- 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.
Vehicles with All Wheel Drive
- Remove the bolts - arrows - and remove the right drive axle heat shield.
- Remove the left drive axle from the transmission flange shaft and tie it up.
• 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.
- Mark the position of the ball joint nuts - arrows -.
- 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 -.
• 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.
Loose support components could cause an accident.
• Secure the securing pin and control arm using the securing pin - arrow - and nut - 1 -.
• 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.
- Press the engine/transmission subassembly slightly forward and remove the driveshaft from the bevel box.
Risk of damaging sealing ring - arrow - in driveshaft flange.
• Press driveshaft horizontally as far back and to right side of vehicle as possible.
• If seal is damaged, driveshaft must be replaced.
- Remove the nuts - 1 - and - 2 - and the particulate filter mount.
- Remove the bolts - 1 - on the cable mounting bracket.
- Remove locking washer - 3 - - arrow - and remove selector lever cable from transmission.
• Ignore - 2 -.
- Remove bolts - arrows -.
- 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.
• Ignore - 1, 2 and 3 -.
- Loosen the fasteners - arrows - and remove the oil pan noise insulation - 1 -.
- Attach the (T10012) to cylinder block with bolt - 1 - and nut - 2 -. Tighten to approximately 20 Nm.
- Place (V.A.G 1383 A) on (T10012) and raise engine/transmission subassembly slightly.
• Use (VAS 5085) to remove bolts for assembly mounting.
- Remove the subframe bolts - arrows - on the engine side.
- Remove the subframe bolts - arrows - on the transmission side completely.
• 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.