ENGINE, REMOVING
Pry Lever - Rmv Outside Mirror 80 - 200
Engine/Transmission Jack V.A.G 1383 A
Step Ladder VAS 5085
Drip Tray for VAS 6100 VAS 6208
Mandrel T10060 A
Assembly Tool T10118
Torque Wrench SAT 8010/3
Note. The engine is removed downward together with the transmission. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Heat insulation sleeves removed during engine removal should be reinstalled in the same location when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.
| CAUTION | Observe safety precautions when disconnecting the battery. Refer to GENERAL INFORMATION . |
Remove tool formed insert under luggage compartment floor covering.
Remove cover -arrow- for battery compartment
Scheme 441
Remove formed insert from over the battery.
With ignition switched off, disconnect Battery Ground (GND) cable -arrow-.
Scheme 442
| WARNING | Risk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening. |
Open cap of coolant expansion tank.
Remove both front wheels.
Remove center noise insulation fasteners -1 to 3-.
Scheme 443
Remove the left and right noise insulation fasteners -1 to 3-.
Scheme 444
Disconnect electrical connector -1- at engine coolant temperature (ECT) sensor (on radiator) -G83-.
Scheme 445
Place VAS 6208 under engine.
Vehicles with drain plug
Turn drain plug -arrow- on radiator left, place assisting hose on supports if necessary.
All Vehicles
Remove lower coolant hose -2- from radiator by removing retaining clamps.
Drain coolant.
Also remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow remaining coolant to drain.
Scheme 446
Note. Shown in illustration on vehicle with Direct Shift Gearbox transmission.
If equipped, remove vacuum hose -2- to air guide hose.
Disconnect air guide hose -1- at throttle valve control module -J338-.
Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.
Remove upper section of air filter housing -arrows-.
Remove filter element.
Pull off air guide cover -1-, disengage clips sideways to do so.
Unclip air duct -2-.
Remove lower section of air filter housing -arrows-.
Remove air filter housing bracket -arrows-.
Disconnect electrical connector -1- for heated oxygen sensor (HO2S) 2 -G108- and -2- for heated oxygen sensor (HO2S) -G39-.
Scheme 447
Free up electrical wiring to oxygen sensors.
Pry off the caps on the wiper arms using a screwdriver.
Scheme 448
Loosen the nuts -arrows- by several turns.
Loosen the wiper arms by gently rocking the wiper arm. Remove the nuts and remove the wiper arms.
Unclip the spray nozzles -arrow-.
Scheme 449
Push spray nozzle with lines still attached back through opening and into plenum chamber.
Remove rubber seal -1- for plenum chamber cover.
Scheme 450
Remove the plenum chamber cover -2-.
Free up the rear engine wiring harness at the partition for plenum chamber.
Remove partition for plenum chamber -arrows-.
Scheme 451
Remove Engine Control Module (ECM). Refer to Removal and Installation .
Separate the electrical connector -2- for engine wiring harness.
Scheme 452
Note. Electrical connector -1- remains connected.
Release pass-through for engine wiring harness -arrow- and pull off upward.
Scheme 453
Vehicle with E-box, old version
Press retaining clamps in direction of -arrow- and remove engine compartment E-box cover.
Scheme 454
Vehicle with E-box, new version
Press both latches in direction of -arrow- and remove engine compartment E-box cover.
Scheme 455
Remove terminal 30 wiring -arrow- at engine compartment E-box and free up.
Scheme 456
Open bracket of wiring -arrows-.
Scheme 457
Free up electrical connector -1- and disconnect.
Scheme 458
Open the underlying wiring guide bracket -2-.
Remove engine wiring harness to control module from wiring.
Note. To unclip spiral clip, use 80-200.
Disconnect secondary air hose at position indicated by -arrow-.
Scheme 459
Free up air hose to Secondary Air Injection (AIR) pump.
Disconnect electrical harness connectors -1-, -3- and -5-.
Scheme 460
Remove protective boot and remove electrical wiring -2- at starter solenoid switch.
Remove Ground (GND) cable -4-.
Remove bolts -1- for bracket -D-.
Scheme 461
Remove retaining clip -A- upward -arrow- and remove selector lever cable from transmission.
Note. Ignore items -B- and -C-.
Remove coolant hoses to heater core on bulkhead -arrows-.
Scheme 462
Disconnect coolant hoses at positions indicated by -arrows-.
Scheme 463
Disconnect electrical connection -1- at throttle valve control module -J338-.
Scheme 464
Disconnect coolant hoses at positions indicated by -arrows-.
Remove throttle valve control module -J338- from intake manifold -arrows-.
Scheme 465
| WARNING | Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection. |
Disconnect following hose connections
Scheme 466
- Coolant hose to reservoir
- Vacuum hose to Evaporative Emission (EVAP) Canister
- Vacuum hose to Leak Detection Pump
- Fuel supply line
- Coolant hose to reservoir
Note. Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap -1- and slide release button -2- to the rear.
Remove hoses and electrical connectors at indicated places
Scheme 467
1 - Electrical connector to evaporative emission (EVAP) canister purge regulator valve -N80
2 - Vacuum hose to brake booster
3 - Vacuum hose to exhaust flap, also to Leak Detection Pump
5 - Vacuum hose to evaporative emission (EVAP) canister purge regulator valve -N80
Note. Ignore -4-.
Remove wiring connection -arrows-.
Remove wiring connections with coolant and vacuum hoses.
Remove heated oxygen sensor (HO2S) 2 -G108- -1- and heated oxygen sensor (HO2S) -G39- -2-.
Scheme 468
Remove bolts -1- and -3- and remove front exhaust pipe support -2-.
Scheme 469
Remove front exhaust pipe nuts and exhaust manifolds -arrows-.
Scheme 470
Remove top mounting bolts for fan shroud -top arrows-.
Scheme 471
Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.
Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.
Remove ribbed belt.
Loosen subframe mounting bolts to engine -arrows- approximately 2 turns.
Loosen subframe mounting bolts to transmission -arrows- approximately 2 turns.
Remove the right vehicle underbody cover -arrows-.
Scheme 472
Disconnect electrical connector -1- to oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- and -2- to oxygen sensor (O2S) 2 behind three way catalytic Converter (TWC) -G131-.
Scheme 473
Remove connector coupling from bracket and free up wiring to oxygen sensors.
Remove front vehicle floor crossmember by removing nuts -1- and -2-.
Scheme 474
Note. Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.
Separate exhaust system at clamping sleeve -3-.
Remove exhaust system bracket -arrows- and remove exhaust system.
Scheme 475
Free up coolant hose at bottom on fan shroud.
Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.
Scheme 476
On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.
Remove bolts -1-.
Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.
Disconnect electrical harness connectors -1- for coolant fans at bottom on fan shroud.
Remove mounting bolts for fan shroud at bottom -bottom arrows-.
Pull out fan shroud downward with both fans.
Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.
| WARNING | The air conditioning refrigerant circuit must not be opened. |
Remove bolts -arrow- for A/C compressor.
Scheme 477
Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.
Remove electrical wire -1- on generator.
Scheme 478
Separate the electrical connector -2-.
Note. Ignore -3-.
Remove upper idler roller -1-.
Scheme 479
Remove mounting bolts -2- and -3- for generator.
Note. Generator can be removed from bracket only with the upper mounting bolt still installed.
Remove generator from accessory assembly bracket.
Remove generator downward and to the left.
Disconnect electrical connector -arrow- to secondary air injection (AIR) solenoid valve -N112-.
Scheme 480
| CAUTION | To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels). |
Have a second technician press brake pedal.
Remove collar bolt -2- at right drive axle -1-.
Scheme 481
Remove right drive axle heat shield from bevel box -arrows-.
Scheme 482
Remove right drive axle. Refer to Removal and Installation .
Remove left drive axle from transmission flange shaft.
Position of flexible disc and bevel box flange are marked to each other.
Remove driveshaft flexible disc at bevel box -arrows-.
Scheme 483
Note. To loosen bolts, counterhold at driveshaft flange/final drive with a lever.
Press driveshaft horizontally as far back as possible.
| CAUTION | Seal -arrow- in driveshaft flange must not be damaged when removing engine/transmission assembly. If seal is damaged, driveshaft must be replaced. Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened. |
Scheme 484
Remove bolts -1 to 3- and remove pendulum support.
Scheme 485
Disconnect electrical connector -1- at oil level thermal sensor -G266-.
Scheme 486
Unclip bracket -2- for electrical wire to oil level thermal sensor -G266- at subframe.
Disconnect electrical harness connector -arrow- at after-run coolant pump -V51-.
Scheme 487
Pull after-run coolant pump -V51-, with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.
Note. Coolant pump remains on the engine with coolant hoses connected.
Remove bolts -1 to 5- and remove accessory assembly bracket.
Screw T40074 to cylinder block -arrows- and tighten to 20 Nm.
Scheme 488
Insert V.A.G 1383 A at T40074 and raise engine/transmission slightly.
Note. Use VAS 5085 to remove bolts for assembly mounting.
Remove subframe mounting bolts at engine -arrows-.
Remove subframe mounting bolts at transmission -arrows-.
Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. While lowering, carefully guide engine/transmission assembly in order to prevent damages.
Pull engine/transmission assembly as far forward as possible and slowly lower it.