Engine, Removing

Special tools and workshop equipment required

Pry Lever: 80-200

Fig 1: Identifying Pry Lever
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Engine Sling - Engine Bracket: 2024A/1 for the Engine Sling: 2024A

Fig 2: Engine Sling - Engine Bracket
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Engine and Gearbox Jack: VAG1383A or Engine and Gearbox Jack: VAS6931

Fig 3: Engine and Gearbox Jack VAS6931 or VAG1383A
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Engine Support: T10497

Fig 4: Identifying Engine Support T10497
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Shop Crane - Drip Tray: VAS6208

Fig 5: Identifying Drip Tray
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Hose Clip Pliers: VAS6362

Fig 6: Hose Clip Pliers
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Locking Pin: T10060A

Fig 7: Identifying Locking Pin
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Commercially Available Step Ladder (not illustrated)
Protective Eyewear
Safety Gloves

Procedure

NOTE:

The engine is removed downward together with the transmission.

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

-- Open the coolant reservoir cap -arrow-.

Fig 8: Identifying Coolant Reservoir Cap

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CAUTION:

The cooling system may be under pressure. 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 suitable towel and carefully opening it.

-- Remove the battery and the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

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

-- Remove the Secondary Air Injection Pump Motor -V101- with the bracket. Refer to Secondary Air Injection Pump Motor -V101-, REMOVING AND INSTALLING .

-- Release the locking mechanism in direction of -arrow- and remove the vacuum hose -1-.

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-- Free up the vacuum hose to the brake booster -1-.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Open the connector couplings -1 and 2- for the fuel lines and remove the fuel lines. Disconnect the couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 9: Identifying Hose Coupling

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-- Release and disconnect the connector -1-.

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-- Remove the bracket -2- with the fuel hoses.

-- Release the retainer with a screwdriver in direction of -arrow- and place the coolant expansion tank on the engine.

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

Fig 10: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -2- from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

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-- Disconnect the connectors -3 and 4- from the bracket.

-- If installed, remove the connector -1- from the bracket and disconnect it.

-- Remove the nut -5- and free up the ground cable.

-- Free up the wires.

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

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

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

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

-- Release and detach the connector from the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Remove the B+ wire from the starter solenoid switch. Refer to STARTER, REMOVING AND INSTALLING .

Vehicles with Automatic Transmission

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-- Disconnect the connectors -1, 2 and 3-.

-- Remove the selector lever cable from the transmission, remove the cable bracket and tie it up with the gearshift lever cable. Refer to OVERVIEW - SHIFT MECHANISM .

Manual Transmission

-- Remove the selector mechanism from the transmission. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

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

Vehicles with DSG Transmission

-- Remove the selector mechanism from the transmission. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

-- Unlock and remove the connector for the DSG Transmission Mechatronic -J743-. Refer to [For transmission(s) 0GC] Mechatronic .

-- If equipped, release the connector for the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- -a- and remove the connector in direction of -b-.

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Continuation for All Vehicles

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-- Remove the nut -2- and free up the ground wire.

-- Remove the left and right front wheels. Refer to WHEEL BOLTS TIGHTENING SPECIFICATION .

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

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

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

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-- Remove the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Remove the A/C compressor with the refrigerant lines still connected from the engine and tie it up on the right side. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .

-- Disconnect the connector -3- from the Oil Level Thermal Sensor -G266- -1-.

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-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Remove the heat shield from the turbocharger. Refer to Removing - Remove the upper heat shield over the turbocharger and the catalytic converter. .

-- Remove the catalytic converter from the engine move to the side and secure it to the vehicle. Refer to Catalytic Converter Removing from the Engine and the Turbocharger .

-- Remove the right drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Remove the right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the left drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Place the Shop Crane - Drip Tray: VAS6208 underneath.

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

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

Fig 11: Identifying Clamp And Upper Left Coolant Hose

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

Fig 12: Identifying Air Guide Hose

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-- Place a cloth under the heater core for the heater, to catch escaping coolant.

Fig 13: Identifying Heater Core Hoses

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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-.

Continuation for All Vehicles

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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 14: Identifying Bolts

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-- Mount the Engine Support - Clamping Piece: T10497/2 on the housing rib of the cylinder block as shown.

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-- Position the Engine Support: T10497 on the cylinder block with the Engine Support - Pin: T10497/1 .

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

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

Fig 15: Identifying Engine Support - Adapter T10497/3

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-- Install the Engine and Gearbox Jack: VAS6931 on the Engine Support: T10497A and slightly lift the engine/transmission assembly.

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

-- Remove the bolts for the engine mount completely.

-- Remove the bolts for the transmission mount completely.

NOTE:

There is a 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.