Engine, Removing: Procedure

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

-- Remove the engine cover, refer to ENGINE COVER .

Fig 1: Identifying Coolant Reservoir Cap

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WARNING:

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

-- Remove the cap -arrow- from the coolant reservoir.

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

-- Remove the air filter housing, refer to AIR FILTER HOUSING .

-- Remove the battery tray, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- Remove the radiator, refer to RADIATOR .

-- Cover the charge air cooler with using suitable workshop equipment, to prevent damage.

-- Loosen the hose clamps -1- and -3-.

Fig 2: Identifying Lower Air Guide Pipe

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-- Disconnect the connector from the Charge Air Pressure Sensor -G31- -arrow-.

-- Remove the bolts -2- and -4- and remove the lower air guide pipe -5-.

-- Remove the vacuum hose -3- from the connector -arrow- and remove the vacuum line -2-.

Fig 3: Identifying Vacuum Pump

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-- Press the vacuum hose release buttons -2- and remove from the vacuum pump -1-.

-- Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger.

Fig 4: Identifying Heater Core Hoses -Arrows-

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NOTE:

There may be a heat shield installed, which dose not need to be removed.

-- Hold the coolant hoses downward and drain the coolant.

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

-- Press the release -arrows- and remove the wires -1- from the Secondary Air Injection Pump Motor -V101- -2-.

Fig 5: Locating The Release

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-- Remove the catalytic converter, refer to CATALYTIC CONVERTER .

WARNING:

Fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.

-- Disconnect the hose coupling -1- and -2-, refer to Removal and Installation .

Fig 6: Identifying Hose Coupling

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-- Disconnect and remove the engine wiring connector from the engine control module, refer to Engine Control Module -J623- .

-- Loosen the nuts -arrows- and disconnect the battery positive cables -1- from the E-box -2-.

Fig 7: Identifying Battery Cables

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-- Squeeze the locking ring on both side and remove the connecting pipe -1-.

Fig 8: Identifying Connecting Pipe And Connector

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-- Carefully unclip the secondary air system bracket -4-.

Fig 9: Identifying Brackets And Clips

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-- Unclip clip -3- and remove both secondary air lines.

-- Remove the ground connection -2- and free up the cable guide -1-.

-- Disconnect the connectors -3-.

Fig 10: Locating Connectors

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-- Open the cable guide -1- locking devices -arrows- and lay the wiring harness on the engine.

-- Disconnect and remove the connector -arrow-.

Fig 11: Identifying Bracket

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

-- Remove the selector lever cable from the transmission, refer to [For transmission(s) 09G] Description and Operation .

NOTE:

Do not bend or kink the selector lever cable.

-- Remove the bolt -4- and rotate the windshield washer fluid reservoir filler tube forward -2-.

Fig 12: Identifying Coolant Expansion Tank And Windshield Washer Fluid Reservoir Filler Tube

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-- Open clip -3- and remove connector -5- from the coolant reservoir -1-.

-- Remove the bolts -arrows- and place the coolant expansion tank -1- on top of the engine with the hoses connected.

-- Loosen the bolt -1- for the engine mount -2- approximately two turns.

Fig 13: Identifying Engine Mount Bolts

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-- Remove bolts -2- on transmission mount -1- 2 turns.

Fig 14: Identifying Transmission Mount Bolts

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-- Pivot tensioning device the direction of the -arrow- to relieve tension on ribbed belt.

Fig 15: Rotating Tensioner

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-- Secure the tensioner with the Locking Pin T10060 A.

CAUTION:

Risk of damage due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioning device.

-- Disconnect the electrical connector -1- on the A/C Compressor Regulator Valve -N280-.

Fig 16: Identifying A/C Compressor Components

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-- Remove the bolts -arrows-.

CAUTION:

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

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

WARNING:

Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

-- Remove A/C compressor with attached coolant hoses from bracket.

-- Remove the left and right driveshaft, refer to Removal and Installation .

-- Remove connector -arrow- from the After-Run Coolant Pump -V51- -1-.

Fig 17: Identifying After-Run Coolant Pump

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-- Remove nut -3- and remove After-Run Coolant Pump -V51- -1- from bracket -2-.

-- Operate the release -arrow- and remove the coolant hose -1- from the controller housing.

Fig 18: Identifying Coolant Hose Release

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-- Remove the bolts -arrows- and move the bracket to the side.

Fig 19: Identifying Bracket

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-- Remove the bolt -arrow- from the bracket -1-.

Fig 20: Identifying Bracket Bolt

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-- Lightly push the wires -2- upward.

-- Connect adapter T10359/3 to the Engine Bracket T10359 from above and tighten.

Fig 21: Identifying Engine/Gearbox Jack Engine Support

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-- Tighten pin T10359/2 with support element -1- from the Transmission Support 3282 to the engine bracket.

-- Place the engine bracket T10359 on the Engine-Transmission Jack VAG1383A and position to the engine/transmission subassembly.

-- After the engine bracket T10359 is positioned correctly, install the bolt -A- with the engine bracket spacer sleeve T10359.

Fig 22: Identifying Engine Support

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-- Secure the engine bracket on engine using the securing element -B- from the Transmission Support 3282 and slightly lift the engine/transmission subassembly.

CAUTION:

Make sure that no components/hoses are damaged, over-stretched or torn when lifting or lowering engine using Engine Support Bridge 10-222A.

-- Carefully remove the bolts -1- for the engine mount -2-.

Fig 23: Identifying Engine Mount Bolts

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-- Remove bolts -2- completely.

Fig 24: Identifying Transmission Mount Bolts

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NOTE:

Depending on the transmission there can be two or three bolts.

CAUTION:

Danger of causing damage to the vacuum lines or electric wires as well as to the engine compartment.

Make sure all the vacuum lines or electric wires between the engine, the transmission and the body are loosened.
Carefully lower and guide the engine/transmission subassembly out of the engine compartment.

-- Carefully lower the engine/transmission sub-assembly in the direction of -arrow 1-.

Fig 25: Identifying Engine Jack

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-- Carefully guide the engine/transmission sub-assembly forward and out to the left in the direction of -arrow 2-.