Engine, Removing

Engine, Removing

• 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 downward 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.

Note the following whenever working inside the engine compartment due to limited space:

• Route all lines and wires in their original locations.

• Ensure sufficient clearance to all moving or hot components.

Special tools, testers and auxiliary items required

• Hose Clamps up to 25 mm Dia. (3094)

• Engine/Trans. Support (T10012)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Torque Wrench (40-200 Nm) (V.A.G 1332)

• Engine-/Gearbox Jack (V.A.G 1383 A)

• Step Ladder (VAS 5085)

• Hose Clip Pliers (VAS 6340)

• Drip Tray for VAS 6100 (VAS 6208)

• Transportation Lock (T10404)

Procedure

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the noise insulation.

• To perform this procedure, the ground cable must be disconnected from the battery. Check if a coded radio is installed. If so, obtain the anti-theft code beforehand.

- Remove the battery, the battery tray bolts - arrows - and the tray.






Risk of destroying electronic components when disconnecting the battery.

• Observe measures for disconnecting the battery.

- Remove the air filter housing with the Mass Airflow (MAF) sensor and connecting pipe. Refer to => [ Air Filter Housing ] Air Filter Housing.

- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.

- Remove the fan shroud. Refer to => [ Fan Shroud with Fan ] Fan Shroud with Fan.

- Remove the radiator. Refer to => [ Radiator ] Radiator.

- Remove the charge air cooler. Refer to => [ Charge Air Cooler ] Charge Air Cooler.

- Remove the charge air cooling pump. Refer to => [ Charge Air Cooling Pump V188 ] Charge Air Cooling Pump V188.

- Remove the subframe.

- Remove the right drive axle shield bolts - 1 - and shield.






- Remove the right drive axle.

- Remove the left drive axle from the transmission.

- Disconnect the vacuum hose - 1 - from the brake booster - 2 -.






- Disconnect and remove the connectors - 1 through 3 -.






- Unclip the connectors from out of the bracket.

• - 1 - Exhaust gas temperature sensor 3, orange connector

• - 2 - Exhaust gas temperature sensor 2, brown connector

• - 3 - Heated oxygen sensor, black connector

- Remove the coolant expansion tank the bolts - 3 -.






- Release and remove the connector from the coolant expansion tank.

- Lay the coolant expansion tank - 2 - on the engine.

Very hot fuel can burn your skin.

• The temperature of the fuel lines and may reach 100 °C (212 °F) after stopping the engine. Allow the fuel to cool down before opening any line connections otherwise there is a danger of scalding.

• Wear protective gloves.

• Wear safety glasses.

- Disconnect fuel line couplings - A and B - and remove the fuel lines.






- Unclip the coolant hose bracket - 1 -.






- Free up the fuel lines.

- Remove the fuel filter housing bolts and nut - 1 through 3 - and lay them on the engine.






• Observe the following information.

- Disconnect and remove the connector - 2 - from the differential pressure sensor.






- Remove the bolts - 1 -.

- Lay the differential pressure sensor and mount on the particulate filter.

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

- Secure the coupling element using the transportation lock (T10404) - arrow -.






- Remove the exhaust pipe - 1 - to particulate filter nuts - arrows -.






- Disconnect the wiring harness from the exhaust gas temperature sensor and remove the connector in the - direction of the arrow -.






- Free up the wire set.

- Disconnect and remove the heater hoses - arrows - from the heater core.






- Disconnect and remove the connector - 2 - from the wastegate bypass regulator valve - 1 -.






- Remove the nuts - arrows - and lay the wastegate bypass regulator valve - 1 - and the vacuum line on the engine.

- Disconnect and remove the connectors - 1 -.






- Unclip the connectors - 1 - and the locking mechanisms - arrows - and open the wire guide - 2 -.

- Disconnect the ground connection - 3 - and free up all wiring harness wires.

- Disconnect and remove the connectors - arrow -.






- Remove the wiring harness from the bracket - 1 -.

- Disconnect and remove the engine wiring connector from the Engine Control Module (ECM). Refer to => [ Engine Control Module ] Engine Control Module.

- Remove the nuts - arrows - and the battery positive cables - 1 - from the E-Box - 2 -.






- Disconnect all other connectors between the starter, transmission and body.

- Free up the wiring.

- Disconnect and remove the connector for the Air Conditioning (A/C) compressor.

- Remove the A/C compressor and secure it to the vehicle body.

There is a risk of damaging the A/C condenser, the A/C compressor and the refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

with a Direct Shift Gearbox (DSG(R))






- Remove the selector mechanism.

- Turn and unlock the Mechatronic unit connector - arrow - and disconnect the connector.

with a Manual Transmission

- Remove the shift mechanism.

- Remove the hose/line assembly and plastic hose from the clutch slave cylinder.

- Disconnect and remove the connector from the park/neutral position switch.

Continuation for All

- Remove the Engine Control Module (ECM). Refer to => [ Engine Control Module ] Engine Control Module.

- Loosen the fasteners - arrows - and remove the oil pan noise insulation - 1 -.






- Install the engine/trans. support (T10012) to the cylinder block with a bolt - 1 - and nut - 2 -. Tighten them to approximately 20 Nm.






- Insert the engine/trans. support (T10012) in the engine-/gearbox jack (V.A.G 1383 A).

- Slightly lift the engine/transmission subassembly.

• Use the step ladder (VAS 5085) to remove the engine mount to engine mount bracket bolts - arrows -.






- Remove the engine mount to engine mount bracket bolts - arrows -.

- Remove the transmission mount to transmission mount bracket - arrows -.






Risk of damaging hose and wiring connections as well as the engine compartment.

• Make sure all the hoses and wires between the engine, transmission, subframe and body have been disconnected.

• Carefully lower and guide the engine/transmission subassembly out of the engine compartment.

• Make certain that there is enough clearance for the A/C compressor.

- Lower the engine/transmission subassembly a little.

- Move the engine/transmission subassembly forward and lower it a little more.