Engine, Removing

Special tools and workshop equipment required

Pry Lever: 80-200
Engine Sling - Engine Bracket: 2024A/1 for the Engine Sling: 2024A
Engine and Gearbox Jack: VAG1383A or : VAS6931
Engine Support: T10497
Shop Crane - Drip Tray: VAS6208
Hose Clip Pliers: VAS6362
Locking Pin: T10060A
Commercially Available Step Ladder
Protective Eyewear
Safety Gloves

Procedure

-- When installing, bring all cable ties back to the same position.

-- Secure all standard production hose clamps. Refer to the Parts Information.

NOTE:

The engine is removed downward together with the transmission.

-- Open the coolant reservoir cap -arrow-.

Fig 1: Identifying Coolant Reservoir Cap

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CAUTION:

The cooling system is under pressure when the engine is warm. There is a risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

- Wear safety gloves.

- Wear protective eyewear.

- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the left and right front wheels. Refer to WHEEL, CHANGING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the left and right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Disconnect the connector -2- on the Engine Coolant Temperature Sensor on Radiator Outlet -G83- -3-.

-- Place the : VAS6208 underneath.

-- Lift the clamp -1- and remove the lower left coolant hose from the radiator.

Fig 2: Identifying Clamp And Connector

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-- Allow the coolant to drain.

-- Lift the clamp -arrow- and remove the lower right coolant hose from the charge air cooling circuit radiator.

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-- Let the remaining coolant drain.

-- If the ribbed belt is to be reinstalled mark the running direction with chalk or a felt-tip pen for reinstallation.

Vehicles with A/C Compressor

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-- To release the tension on the ribbed belt, turn the tensioner counter-clockwise in the direction of -arrow-.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley.

-- Secure the tensioner using the : T10060A .

-- Remove the ribbed belt.

CAUTION:

Danger of frostbite from refrigerant.

- Do not open the A/C system refrigerant circuit.

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

Fig 3: Identifying A/C Compressor Components

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-- Remove the A/C compressor bolts -arrows-.

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

-- Remove the A/C compressor with the refrigerant lines connected and tie it up on the right side.

Continuation for All Vehicles

Fig 4: Identifying Clamp And Upper Left Coolant Hose

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-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

-- Lift the clamp -arrow- and remove the upper right coolant hose from the charge air cooling circuit cooler.

Fig 5: Identifying Air Guide Hose

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-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Attach the : VAS531003 to the vehicle as shown.

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-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the battery and the battery tray. Refer to Battery, Removing and Installing .

-- Open the retainer in direction of -arrow- and remove the vacuum hose -1-.

Fig 6: Identifying Cover And Retainers

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-- Free up the vacuum hose on the air duct pipe -2-.

Vehicles without Parking Heater

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-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

Vehicles with Parking Heater

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-- Loosen the clip and hose clamp and remove both coolant hoses -arrows-.

Vehicles with Engine Preheating Element -Z97-

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-- Unclip the locking mechanism -arrow-.

-- Disconnect the cable set -1- from the Engine Preheating Element -Z97- -2-.

-- Unclip all cable ties from the wiring harness -1- on the engine.

-- Secure the wiring harness on the side on the vehicle.

-- Remove the lower coolant hose on the Engine Preheating Element -Z97- and remove the coolant pipe.

-- Remove the nuts -arrows- and remove the Engine Preheating Element -Z97- with the bracket.

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Continuation for All Vehicles

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-- Remove the bolt -2-.

-- Mark the position of the clamp for reinstallation.

-- Remove the screw-type clamp -1-.

-- Remove the nuts -arrows- and tie up the catalytic converter -3-.

-- Remove the bolts -arrows- and remove the bracket.

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-- Place a cloth underneath to catch escaping coolant.

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-- Loosen the hose clamp -1- and remove the coolant hose.

-- Pay attention to the guidelines for clean working conditions in the repair information.

-- First push the hose coupling -1- downward and then press the release buttons in direction of -arrows-.

-- Remove the hose coupling with the release buttons pressed.

Fig 7: Identifying Hose Coupling

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-- Press the release button on the hose -2- to the EVAP canister.

-- Remove the hose and free it up.

-- Remove the air duct hose -2-.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Use the : 80-200 for removing the spiral clips in the following steps.

Fig 8: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the upper connector -1- from the Engine/Motor Control Module -J623-. Refer to ENGINE/MOTOR CONTROL MODULE .

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-- Remove the connectors -2 and 3- from the bracket and disconnect them.

-- Free up the wires.

-- Disconnect the connector -2-.

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-- Push the B+ terminal protector -1- back and disconnect the B+ wire from the starter solenoid switch.

-- Remove the ground cable from the body.

-- Release the retainers in direction of -arrows- and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver in direction of -arrow-, remove the cover -1- for the engine compartment E-box upward.

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-- Remove the nut -arrow-, disconnect and free up the wires.

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-- Disconnect the connectors -1 and 2-.

Fig 9: Component location Transmission Neutral Position Sensor -G701- /Back-Up Lamp Switch -F4-

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Manual Transmission

-- Remove the selector mechanism from the transmission. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING (02S) or SHIFT MECHANISM, REMOVING AND INSTALLING (09S) .

-- Remove the clutch slave cylinder. Refer to CLUTCH SLAVE CYLINDER, REMOVING AND INSTALLING (02S) .

DSG^® transmission

-- Remove the selector lever cable, the Mechatronic connector and all brackets from the transmission. Refer to [For transmission(s) 0GC] Transmission, Removing and Installing , [For transmission(s) 02S] Transmission, Removing and Installing or [For transmission(s) 02Q] Transmission, Removing and Installing

Continuation for All Vehicles

Fig 10: Identifying Engine Mount Bracket Bolts

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-- Loosen the bolts -arrows- on the engine mount approximately two turns.

-- Loosen the bolts -arrows- on the transmission mount approximately two turns.

Fig 11: Identifying Bolts

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-- Disconnect the connector -1- from the Oil Level Thermal Sensor -G266-.

Fig 12: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Disengage the wire from the bracket -2-.

-- Remove the left and right coupling rod nuts -arrow- on the stabilizer bar.

Fig 13: Identifying Left And Right Coupling Rod Nuts

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

Fig 14: Identifying Support Bracket, Pendulum And Bolts

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

Fig 15: Drive Axle Heat Shield

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-- Remove the left and right nuts -arrows- for the ball joint.

Fig 16: Ball Joint Lower Nuts

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-- If equipped, remove the nut -arrow- from the Left Front Level Control System Sensor -G78-.

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-- Disengage the left and right ball joint from the transverse link.

-- Remove the left and right drive axle from the transmission and tie them up. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

NOTE:

Be careful not to damage the protective coating on the drive axle.

-- Tilt the left suspension strut outward and support it with the : 2024A/1 as shown.

Fig 17: Securing Pin And Control Arm Secured Using Securing Pin And Nut

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-- Secure the pin and ball joint using the retainer -arrow- and nut -1-.

-- Fasten the right ball joint -2- to the transverse link -1- with the nut -arrow- as shown.

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-- Mount the T10497/2 on the housing rib of the cylinder block as shown.

-- Position the T10497 with Pins T10497/1 on the cylinder block.

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-- Install the bolt -1- through the hole "B" on the : T10497 and tighten to 20 Nm.

-- Attach the : T10497/3 to the : T10497 and tighten the bolt -1- to 20 Nm.

Fig 18: Identifying Engine Support - Adapter T10497/3

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-- Install the : VAS6931 on the : T10497A and slightly lift the engine/transmission assembly.

NOTE:

Use a commercially available step ladder to remove the assembly mount bolts.

-- Completely remove the engine mount bolts -arrows-.

Fig 19: Identifying Engine Mount Bracket Bolts

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-- Completely remove the transmission mount bolts -arrows- completely.

Fig 20: Identifying Bolts

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NOTE:

Risk of damaging the vacuum lines or wires as well as the engine compartment.

Make sure all the vacuum lines or wires between the engine, the transmission, the subframe and the body are loosened.

Carefully guide the engine/transmission assembly with the subframe out of engine compartment when lowering.

-- Slightly lower the engine/transmission assembly.

-- Then push the transmission side of the engine/transmission assembly forward and then continue to lower it.