Engine, Removing
Engine, Removing
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
Special tools, testers and auxiliary items required
• Lifting tackle (3033)
• Hose clamps up to 25 mm diameter (3094) (vehicles with manual transmission)
• Torque Wrench (V.A.G 1331)
• Torque Wrench (V.A.G 1332)
• Step ladder (VAS 5085)
• Shop crane (VAS 6100)
• Drip tray for workshop crane (VAS 6208)
• Spring-type clip pliers (VAS 6362)
• Engine bung set (VAS 6122)
CAUTION!
• Follow the safety precautions when working on the diesel direct injection system. Refer to --> [ Safety Precautions ] Safety Precautions.
• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] Clean Working Conditions.
Always follow these instructions before and during work.
• --> [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview
• --> [ Cooling System Components Assembly Overview, Body Side ] [1][2]Cooling System Components Assembly Overview, Body Side
• --> [ Fuel Filter Assembly Overview ] Fuel Filter Assembly Overview
• --> [ Turbocharger with Exhaust Manifold and Attachments Assembly Overview ] Turbocharger with Exhaust Manifold and Attachments Assembly Overview
• --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview
• --> [ Particulate Filter with NOx Absorption Catalytic Converter Assembly
Overview ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview
• --> [ Exhaust Gas Recirculation System Components Assembly Overview ] Service and Repair
• Hose connections are secured with either spring-type or clamp-type clips.
• Always replace clamp-type clips with spring-type clips.
• Pliers for spring clamps (VAS 6362) or Hose clamp pliers (VAS 6340) are recommended for installing spring clamps.
• To perform the procedure, the battery ground cable must be disconnected. Check whether a coded radio is installed. If so, obtain antitheft coding beforehand.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• The engine is removed forward together with the transmission.
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
Requirements
• Ignition switched off.
• Engine must be cold.
- Check the DTC memory for all control modules before removal. Refer to "Vehicle Self-Diagnosis".
- Remove engine cover. Refer to --> [ Engine Cover ] Engine Cover.
- Remove air filter housing. Refer to --> [ Air Filter Housing ] Air Filter Housing.
- Remove intake hose. Refer to --> [ 1 Intake Tube ] Air Filter Assembly Overview between the MAF sensor and the intake scoop. Loosen the hose clips with hose clip pliers (VAS 6362).
CAUTION!
Electronic components could be destroyed when the battery is disconnected. Follow the required steps when disconnecting the battery!
- With ignition switched off, disconnect the ground cable - arrow - to the battery..
- Remove the battery and battery tray - arrows -.
- Disconnect connector on the ECM:
Refer to:
• --> [ Engine Control Module without Anti-Theft Protection ] Engine Control Module without Anti-Theft Protection
• --> [ Engine Control Module with Anti-Theft Protection ] Engine Control Module with Anti-Theft Protection
- Release engine wiring harness bushing - A - and remove it upward - arrow -.
- Remove E-box cover by slide both latches in direction of - arrow -.
- Disconnect wire from the generator - A - and the wire from the battery - B - at the fuse holder.
- Open all cable guide locking mechanisms on the longitudinal member - arrows -.
- Disconnect connector - arrow - on the starter.
- Remove Ground wire on the transmission bracket.
- Disconnect the orange connector for the bank 1 exhaust gas temperature sensor 2 - 1 -, the black connector for the exhaust gas temperature sensor 1 - 2 - and the black connector for the heated oxygen sensor - 3 - at the engine bulkhead.
- Disconnect connector - 2 - from the exhaust pressure sensor 1 - 1 -.
- Remove bolt - 4 - and bracket - 3 - with exhaust pressure sensor 1 - 1 - in direction of - arrow - and lay them aside. The control wires remain connected.
- Remove heat shield and disconnect connector from the exhaust pressure sensor 2 --> [ 1 ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview.
- Remove control wire --> [ 5 Control Wire ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview from the exhaust pressure sensor 2. Remove hose clip with hose clip pliers (VAS 6362).
- Remove bolts and bracket with exhaust pressure sensor 2 and lay them aside (the control wire to the particulate filter remains connected).
- Remove the wastegate bypass regulator valve from the retainer and lay it on the engine.
- Remove windshield washer fluid reservoir filler neck.
- Remove coolant reservoir --> [ 7 Coolant Reservoir ] [1][2]Cooling System Components Assembly Overview, Body Side from the body. The coolant lines remain connected.
- Remove fuel filter. Refer to --> [ Fuel Filter ] Fuel Filter.
- Remove auxiliary fuel pump. Refer to --> [ Auxiliary Fuel Pump ] Auxiliary Fuel Pump.
- Disconnect vacuum hose from the brake booster.
- Remove insulation pan.
- Drain the engine coolant. Refer to --> [ Cooling System, Draining and Filling ] [1][2]Cooling System, Draining and Filling.
- Disconnect all coolant lines between engine and radiator. Refer to --> [ Cooling System Components Assembly Overview, Body Side ] [1][2]Cooling System Components Assembly Overview, Body Side.
- Disconnect heat exchanger coolant hoses at the engine bulkhead.
• Collect any leaking fluid with the drip tray for VAS 6100 (VAS 6208).
- Disconnect all connecting hoses between the engine and charge air. Refer to --> [ Charge Air Cooler Components Assembly Overview ] Charge Air Cooler Components Assembly Overview.
- Extract refrigerant from air conditioning system.
- Remove refrigerant lines on the A/C compressor and condenser and secure them on the body.
- Remove lock carrier.
- Remove right drive axle heat shield - arrows -.
- Remove drive axles only at the transmission.
- Remove lower bracket --> [ (item 26) Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview for the particulate filter.
• Remove nuts above the bracket with the ratchet wrench (T10384).
- Remove exhaust gas recirculation filter --> [ 9 Filter ] Service and Repair.
- Remove particulate filter from the upper bracket --> [ 31 Bracket ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview and remove bracket at the cylinder head.
- Remove clamp --> [ 10 Securing Clamp, 7 Nm ] Particulate Filter with NOx Absorption Catalytic Converter Assembly Overview between the particulate filter and turbocharger.
- Secure particulate filter on the body without tension.
Manual Transmission
- Remove shift mechanism from the transmission..
- Pinch off the hose leading to the sensor cylinder using hose clamps up to 25 mm (3094).
- Pull clip - arrow - for the hydraulic clutch hydraulic line - A - out as far as the stop.
- Remove hydraulic line - A - from the ventilator/slave cylinder and seal it off.
CAUTION!
Do not operate clutch pedal any more.
DSG Transmission
- Disconnect selector lever cable from the transmission.
All Vehicles
- Remove all remaining electrical wires necessary from engine/transmission and set aside.
• Verify that all hose and line connections between engine, transmission and body have been disconnected.
- Remove bolts - 1 to 3 - and pendulum support.
- Engage the lifting tackle (3033) as follows and support the "engine/transmission assembly" with the shop crane (VAS 6100).
Vibration damper side:
• Position 2.
Flywheel side:
• Position 8.
- Remove subframe bolts - arrows - on engine.
Manual Transmission
- Remove subframe bolts - arrows - on transmission.
DSG Transmission
- Remove subframe bolts - arrows - on transmission.
All Vehicles
• When removing the engine/transmission assembly, guide it out carefully to avoid damaging it.
- Raise the "engine/transmission assembly" slightly and remove it toward the front.
- Separate transmission from the engine. Refer to --> [ Transmission and Engine, Separating and Assembling ] Engine and Transmission, Separating and Assembling.
Secure the engine on the Engine and Transmission Holder (VAS 6095) whenever working on it. Refer to --> [ Engine, Securing on Engine and Transmission Holder VAS 6095 ] Engine, Securing on Engine and Transmission Holder VAS 6095.