Engine, Removing

Special tools and workshop equipment required

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
Spring Type Clip Pliers VAS 5024 A
Step Ladder VAS 5085
Engine/Trans. Support T10012
Cable Ties

NOTE:

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

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.

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

Procedure

-- Disconnect the battery ground cable with the ignition turned off. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) CBTA, CJAA, CBUA, CCTA, CBFA] Removal and Installation .

-- Remove the engine cover with air filter. Refer to ENGINE COVER WITH AIR FILTER .

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

Fig 1: Identifying Battery Holder Bolts

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-- Remove the plenum chamber cover. Refer to Removal and Installation .

-- Remove the plenum chamber bulkhead. Refer to Description and Operation .

-- Disconnect the harness connector from the Engine Control Module (ECM).

-- Release the pass through for the engine harness -arrow- and pull it off upward.

Fig 2: Identifying Pass-Through For Engine Wiring Harness

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-- Remove the E-box cover by sliding both latches in the -direction of the arrows-.

Fig 3: Identifying E-Box Cover And Latches

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-- Remove the nuts, the generator cable -A- and the battery cable -B- from the fuse holder.

Fig 4: Identifying Generator Cable -A- And Battery Cable -B-

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-- Remove the bolt and the ground wire -arrow- from the longitudinal member.

Fig 5: Ground (GND) Cable On Longitudinal Member

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-- Open the locking mechanisms -arrows- on the wire guide on the longitudinal member.

Fig 6: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

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-- Free up the electrical connector -1- and disconnect it.

Fig 7: Identifying Electrical Connector -1- And Wiring Guide Bracket -2-

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-- Open the underlying wiring guide bracket -2-.

-- Take the ECM wiring harness out of the wiring router and lay it on the engine.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Lay a cloth at the connection points before loosening the hose connections. Then reduce the pressure by carefully removing the hose.

-- Disconnect the vent line -1- and the fuel supply line -2-.

Fig 8: Identifying Fuel Supply Line

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-- Disconnect the vent line -2- and remove the Evaporative Emission (EVAP) canister with the hoses, upward out of the mount.

Fig 9: Identifying Ventilation Line & EVAP Canister

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-- Remove the noise insulation. Refer to Description and Operation

-- Remove the left and right front wheel housing liners. Refer to Removal and Installation .

-- Remove the charge air hoses -arrows-.

Fig 10: Disconnecting Charge Air Hoses

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-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 11: Right Drive Axle Heat Shield

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-- Remove the driveshaft. Refer to REMOVAL AND INSTALLATION .

-- Remove the right and left drive axles. Refer to Removal and Installation .

-- Remove the exhaust pipe with catalytic converter. Refer to EXHAUST PIPE WITH CATALYTIC CONVERTERS .

-- Move the lock carrier into the service position. Refer to Description and Operation .

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

-- Evacuate the Air Conditioning (A/C) system. Refer to "Refrigerant Circuit" in Description and Operation .

-- Remove the refrigerant line bolt -arrow- and line from the A/C compressor.

Fig 12: Identifying Removal Of A/C Line From Compressor

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-- Remove the refrigerant line bolt -arrow- and line from the A/C condenser.

Fig 13: Disconnecting Refrigerant Line From Condenser

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-- Remove the pendulum support bolts -1, 2 and 3- and remove the pendulum support.

Fig 14: Identifying Pendulum Support & Bolts

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-- Disconnect all remaining electrical connectors necessary from the engine and transmission and set aside.

-- Disconnect all coolant, vacuum and intake connections from the engine.

-- Remove the shift mechanism from the transmission. Refer to SHIFT MECHANISM .

-- Clamp off the hose -A- to the clutch slave cylinder using a hose clamp up to 25 mm dia.3094.

Fig 15: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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-- Pull the hose/line assembly clip -arrow- out as far as the stop.

-- Disconnect the hose/line assembly from the slave cylinder.

CAUTION:

The clutch pedal must no longer be pressed down.

-- Remove the coolant recirculation pump -V50- bolts -arrows-.

Fig 16: Identifying Removal Of Coolant Pump V50

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-- Install the engine/trans. support T10012 onto the engine-/gearbox jack V.A.G 1383 A.

-- Install the engine/trans. support T10012 to the engine as shown and tighten the bolt -1- and nut -2- to 20 Nm.

Fig 17: Attaching Engine Support T10012 On Engine

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-- Support the engine and transmission using the engine-/gearbox jack V.A.G 1383 A.

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

Fig 18: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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

Fig 19: Identifying Removal Of Assembly Mounting On Transmission Side From Transmission Bracket

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NOTE:

Use the step ladder VAS 5085 to remove the bolts.

Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.

-- Carefully lower the engine and transmission.