Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Lifting Tackle (3033)
• Be sure to obtain the radio anti-theft code because it will be necessary to disconnect the battery ground cable later in the procedure.
• The engine is removed forward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all wires and lines so that the original path is followed.
• Ensure sufficient clearance to all moving or hot components.
- Turn off the ignition and disconnect the battery ground cable.
- Remove the air filter housing with the Mass Airflow (MAF) sensor and intake hose. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.
- Remove the battery.
- Remove the battery tray bolts - arrows - and tray.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the fuel filter.
- Remove the auxiliary fuel pump/fuel pump 2.
- Remove the noise insulation.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Remove the lock carrier.
- Remove the bolt - arrow - and move the windshield washer fluid reservoir filler tube to the side.
- Remove the coolant expansion tank and lay it on the engine.
- Remove the bolt - arrow -, turn the adapter - A - to the right and remove it.
- Remove the vacuum hoses - 1 and 2 - for the charge air regulation.
- Disconnect the connectors for the exhaust gas temperature sensor 1 (- 1 -), the heated oxygen sensor (- 3 -) and for the exhaust gas temperature sensor 4 (- 2 -).
- Disconnect the exhaust gas temperature sensor 3 connector - 1 - (attached behind the bracket).
- Guide the wires out of the mounts on the plenum chamber bulkhead and on the turbocharger.
- Remove the vacuum line from the vacuum pump.
- Remove the refrigerant line bolt - arrow - from the Air Conditioning (A/C) compressor.
- Remove the refrigerant line from the A/C compressor and move it to the side without bending it.
- Open the quick-release couplings for the heater core - arrows - on the plenum chamber bulkhead.
- Remove the nut and starter positive wire - arrow - from the central electronics and place the wire on the engine.
with a Direct Shift Gearbox (DSG(R))
- Remove the selector mechanism from the transmission.
- Turn and unlock the Mechatronic unit connector - arrow - and disconnect the connector.
with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Disconnect the hose/line assembly or pipe from the clutch slave cylinder.
Continuation for All
- Remove the windshield wiper arms.
- Remove the plenum chamber cover.
- Remove the plenum chamber bulkhead.
- Remove the Engine Control Module (ECM). Refer to one of the following:
=> [ Engine Control Module, without an Anti-Theft Immobilizer ] Engine Control Module, Without an Anti-Theft Immobilizer.
=> [ Engine Control Module, with an Anti-Theft Immobilizer ] Engine Control Module, With an Anti-Theft Immobilizer.
- Release the engine wiring harness connector - arrow - and disconnect it from the ECM.
- Disconnect the connectors - 1 and 2 - on the left longitudinal member.
- Disconnect the ground wire from the transmission.
- Open the locking mechanism - A - inside the plenum chamber bulkhead.
- Remove the upper part upward and remove the engine wiring harness from the wire guide.
- Disconnect all connectors between the starter, the transmission and the body.
- Remove the bolt - arrow - at the top of the particulate filter bracket and loosen the bolt on the cylinder head just one turn.
- Disconnect the oil level thermal sensor connector.
- Remove the drive axles.
- Remove the bolts - 1 through 3 - and then remove the pendulum support.
- Loosen the clamp - 1 - between the particulate filter and the turbocharger.
- Remove the nuts above the particulate filter mount using the wrench SW13 (T10384).
- Remove the nuts - arrows - for the particulate filter mount - A - on the crankcase and remove the mount.
- Move the particulate filter to the side and secure it to the plenum chamber bulkhead.
• Verify that all hose and line connections between the engine, transmission and body have been disconnected.
- Install the lifting tackle (3033) as follows and support the "engine/transmission subassembly" using the shop crane - load cap = 700-1200 KG (VAS 6100).
Vibration damper side:
• Position 2.
Flywheel side:
• Position 8.
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• When removing the "engine/transmission subassembly", guide it out carefully to avoid damaging it.
- Lower the "engine/transmission subassembly" slightly and remove it toward the front.
Secure the engine to the engine and transmission holder (VAS 6095) whenever working on it. Refer to => [ Engine, Securing to the Engine and Transmission Holder ] Procedures.