Engine, Removing: Procedure

WARNING: This page is about a different variant/trim than selected.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the noise insulation. Refer to Removal and Installation .

NOTE:

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 battery tray. Refer to Removal and Installation .

Fig 1: Identifying Battery Housing Bolts

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CAUTION:

Risk of destroying electronic components when disconnecting the battery.

Observe measures for disconnecting the battery.

-- Remove the air filter housing with the Mass Airflow Sensor -G70- and connecting pipe. Refer to AIR FILTER HOUSING .

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Remove the fan shroud. Refer to FAN SHROUD WITH FAN .

-- Remove the radiator. Refer to RADIATOR .

-- Remove the charge air cooler. Refer to CHARGE AIR COOLER .

-- Remove the charge air cooling pump. Refer to Charge Air Cooling Pump -V188- .

-- Remove the subframe. Refer to Removal and Installation .

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

Fig 2: Locating Heat Insulation Sleeve Bolts

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-- Remove the right drive axle. Refer to Removal and Installation .

-- Remove the left drive axle from the transmission. Refer to Removal and Installation .

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

Fig 3: Identifying Vacuum Hose

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

Fig 4: Identifying Connectors

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-- Remove the connector from the holder.

Exhaust Gas Temperature Sensor 2 -G448- - Orange connector
Exhaust Gas Temperature Sensor 3 -G495- - Brown connector
Heated Oxygen Sensor -G39- - Black connector

-- Remove the bolts -3- and the coolant expansion tank -2-.

-- Unlock and disconnect the connector on the coolant expansion tank.

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

Fig 5: Identifying Coolant Reservoir, Bolts, And Connector

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WARNING:

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. Disconnecting the couplings, refer to Description and Operation .

Fig 6: Identifying Fuel Line Couplers

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-- Unclip the coolant hose bracket -1-.

Fig 7: Identifying Coolant Hose Bracket

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-- Free up the fuel lines.

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

Fig 8: Fuel Filter, Fuel Hoses And Bolts

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NOTE:

Observe the following information. Refer to "Fuel Filter Overview" in the Description and Operation .

-- Disconnect and remove the connector -2- from the Differential Pressure Sensor -G505- in the -direction of the arrow-.

Fig 9: Identifying Bolts

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-- 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 VAS6122.

-- Secure the coupling element using the Transportation Lock T10404 -arrow-.

Fig 10: Identifying Transportation Lock

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

Fig 11: Identifying Exhaust Pipe Nuts

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-- Disconnect the wiring harness from the Exhaust Gas Temperature Sensor 4 -G648- and remove the connector in the -direction of the arrow-.

Fig 12: Identifying Connector For Exhaust Gas Temperature Sensor

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-- Free up the wire set.

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

Fig 13: Identifying Spring Clamps And Radiator Coolant Hoses

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-- Disconnect and remove the connector -2- from the Wastegate Bypass Regulator Valve -N75- -1-.

-- Remove the nuts -arrows- and lay the Wastegate Bypass Regulator Valve -N75- -1- and the vacuum line on the engine.

Fig 14: Identifying Connector And Wastegate Bypass Regulator Valve

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-- Disconnect and remove the connectors -1-.

Fig 15: Connectors And Cable Guide

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-- 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 -arrows-.

Fig 16: Identifying Bracket

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-- 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 .

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

Fig 17: Identifying Battery Cables

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-- 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. Refer to REMOVAL AND INSTALLATION .

CAUTION:

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®)

Fig 18: Mechatronic Unit Connector

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-- Remove the selector mechanism. Refer to[For transmission(s) 02Q] Removal and Installation .

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

With a Manual Transmission

-- Remove the shift mechanism. Refer to [For transmission(s) 02Q] Removal and Installation .

-- Remove the hose/line assembly and plastic hose from the clutch slave cylinder. Refer to [For transmission(s) 02Q] Removal and Installation .

-- Disconnect and remove the connector from the Park/Neutral Position Switch -E17-.

Continuation for All

-- Remove the Engine Control Module -J623-. Refer to ENGINE CONTROL MODULE .

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

Fig 19: Identifying Oil Pan Noise Insulation

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-- Install the Engine/Trans. Support T10012 to the cylinder block with a bolt -1- and nut -2-. Tighten them to approximately 20 Nm.

Fig 20: Attaching Engine/Trans. Support T10012 To Cylinder Block

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-- Insert the Engine/Trans. Support T10012 in the Engine/Gearbox Jack VAG1383A.

-- Slightly lift the engine/transmission subassembly.

NOTE:

Use the Step Ladder VAS 5085 to remove the engine mount to engine mount bracket bolts -arrows-.

Fig 21: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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

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

Fig 22: Identifying Bolts For Subframe Mount At Transmission

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CAUTION:

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.