Engine, Removing

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS 6931

Fig 1: Engine and Gearbox Jack VAS6931 or VAG1383A
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Engine/Gearbox Jack - Engine Support: T10359 A

Fig 2: Identifying Engine/Gearbox Jack Engine Support
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Engine/Gearbox Jack - Pin: T10359/2
Adapter: T10359/3
Securing element from the Transmission Support: 3282

Fig 3: Identifying Transmission Support 3282
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Pry Lever: 80 - 200

Fig 4: Identifying Pry Lever
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Protective Eyewear
Safety Gloves
Step Ladder

NOTE:

The engine with transmission is removed downward. For this reason it is necessary to remove the subframe with the steering gear.

Procedure

Fig 5: 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.

-- Open the coolant reservoir cap -arrow-.

-- Remove the left and right front wheel housing liners. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Remove the subframe with the steering gear. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Separate the left drive axle from the flange shaft and tie upward. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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

NOTE:

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

-- Disconnect the connector -1-.

Fig 6: Component Location Engine Coolant Temperature Sensor

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-- Place the Shop Crane - Drip Tray: VAS 6208 underneath.

-- Lift the clamp -3- and remove the lower right coolant hose from the radiator and drain the coolant.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

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

-- Remove the bolt -arrow- on the left and right.

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-- Unclip and remove the lower section -1- of the air duct.

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

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

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-- Remove the battery tray -1-. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Disconnect the vacuum hose -2-.

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-- Press the release button on the vacuum hose -1- and remove the hose from the vacuum pump.

Vehicles without Parking Heater:

Fig 7: Identifying Heater Core Hoses

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

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

Vehicles with Parking Heater:

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-- Loosen the hose clamp -1-, lift the clamps -arrows- and remove the coolant hoses.

Continuation for All Vehicles:

Fig 8: Heated Oxygen Sensors

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-- Remove the connectors -1 and 2- from the bracket and disconnect them. Then free up the wires.

Vehicles with a particulate filter:

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-- Remove the bolt -3- and loosen the control line for the Exhaust Pressure Sensor 1 -G450- -4- from the exhaust pipe.

-- Loosen the hose clamps -arrows- and remove the pressure hoses -1 and 2- from the control line for the Exhaust Pressure Sensor 1 -G450-.

Continuation for All Vehicles:

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-- Remove the bolt -2- and the screw-type clamp.

-- Remove the nuts -1 and 3- and tie up the catalytic converter to the rear. (Shown with the engine removed.)

Fig 9: Identifying Expansion Tank

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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.

-- Disconnect the hose couplings -1 and 2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING . Loosen the hose clamp from the expansion tank -3-.

-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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

Fig 10: Identifying Clamp And Upper Left Coolant Hose

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NOTE:

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

Fig 11: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -1- from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

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

-- Free up the wires.

-- Release the retainers in the 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 the 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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Vehicles with Manual Transmission:

Fig 12: Identifying Connector

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-- Disconnect the connector -2-.

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

-- Remove the nut -3- and remove the ground wire.

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- Disconnect the left front connectors from the transmission:

Fig 13: Identifying Park/Neutral Position Switch

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For the Transmission Neutral Position Sensor -G701-
For the Back-Up Lamp Switch -F4-

-- Remove the shift and selector cable from the transmission, remove the cable bracket and move it to the side with the cables. Refer to the appropriate Service Information .

-- Clamp the hose/line assembly -A- to the slave cylinder with the Hose Clamps - Up To 25mm: 3094 .

Fig 14: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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

-- Remove pipe/hose line assembly from the slave cylinder ventilator.

Vehicles with Dual-Clutch Transmission:

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-- Disconnect the connector -1-.

-- Push the B+ terminal protector -3- back and disconnect the B+ wire from the starter solenoid switch.

-- Loosen the nut -arrow- and remove the ground wire.

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- To discharge static electricity, touch a ground by hand (without gloves).

-- Do not touch connector terminals in the transmission connector with hands.

-- Disconnect the connector -2- for the Dual-Clutch Transmission Mechatronic -J743- by turning the twist lock counter-clockwise.

-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to the appropriate Service Information .

Vehicles with automatic transmission:

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-- Disconnect the connector -4-, open the locking mechanism and lay the engine wiring harness -3- on the engine.

-- Pry the selector lever cable -1- off the selector lever -2-, for example, using an open end wrench.

-- Remove the connector -6- from the Multifunction Transmission Range Switch -F125- and free up the wire on the bracket.

-- Remove the bolts -5- from the cable bracket -4-. Do not remove the lock washer -3-.

-- Disengage the selector lever cable -1- from the clip -arrow-.

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NOTE:

Do not bend or kink the selector lever cable.

So that the cable is not damaged when removing and installing the transmission, secure the cable using for example a cable tie on a suitable location on the body.

-- Remove the connector from the transmission as follows. Push the retainer -1- in the direction of the arrow, open the bracket -2- and then remove the connector -3- from the transmission.

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-- Disconnect the connections from the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Remove the bolt -A- and remove the ATF lines -2- from the thermostat -1-.

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Ignore the bolts -B-.

Continuation for all:

Fig 15: Identifying Bolts

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

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

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-- Loosen the hose clamp -1 and 2- and remove the right charge air hose.

Fig 16: Identifying Clamps

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-- Seal the open lines and connections with clean plugs from the Engine Bung Set: VAS 6122 .

-- Free up the coolant hose -3-.

Fig 17: Disconnect Charge Air Pressure Sensor Connector

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-- Remove the bolts -arrows-.

-- Loosen the hose clamp -2-.

-- Disconnect the connector -1- from the Charge Air Pressure Sensor -G31-.

-- Remove the air duct pipe.

-- Loosen the hose clamps -arrow- on the charge air cooler and remove from the left charge air hose -A- from the charge air cooler.

Fig 18: Removing Change Air Hose

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-- Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation.

Fig 19: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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-- Pivot the tensioner clockwise in the direction of -arrow- to release the tension on the ribbed belt.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioner. If necessary, remove the Locking Pin: T10060A .

Fig 20: Identifying A/C Compressor Components

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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-.

-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side. While doing so, do not bend, twist or stretch the refrigerant lines and hoses.

AWD vehicles

-- Loosen the clamping sleeve -arrow- and push it toward the rear.

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-- Remove the catalytic converter with the front exhaust pipe.

-- Remove the bolts -A and B- on the bevel box and remove the heat shield -1-.

Fig 21: Driveshaft Heat Shield

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-- Mark the position of the driveshaft to the flange on the bevel box.

Fig 22: Mark Position Of Driveshaft

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-- To loosen or tighten, counterhold the driveshaft on the rear final drive.

Fig 23: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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-- Remove the driveshaft on the front bevel box -arrows-.

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-- Secure the Support Bridge: T10323 with a bolt in the inside rear threaded hole for the subframe.

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-- A subframe bolt is suitable for this.

-- Place a cloth -A- on the Support Bridge: T10323 .

-- Remove the driveshaft from the bevel box.

Continuation for all vehicles

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-- Remove bolt -arrow- and push the bracket for the wiring harness to the side.

-- Fasten the Adapter: T10359/3 on the Engine/Gearbox Jack - Engine Support: T10359A as shown.

Fig 24: Identifying Engine/Gearbox Jack Engine Support

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-- Tighten the Engine/Gearbox Jack - Pin: T10359/2 onto the engine bracket with the securing element -A- from the Transmission Support: 3282 .

-- Place the Engine/Gearbox Jack - Engine Support: T10359 in the Engine and Gearbox Jack: VAS 6931 .

-- Position the Engine/Gearbox Jack - Engine Support: T10359A on the cylinder block. Fasten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 25: Identifying Engine Support

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-- Secure the engine with the support element -B- and lift the engine with the transmission.

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

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

Fig 26: Identifying Bolts

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-- Carefully drain the engine/transmission assembly while doing so check is all vacuum lines or wires between the engine, transmission and body are separated.

Fig 27: Identifying Engine Jack

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