ENGINE, REMOVING
Special tools and workshop equipment required
- Pry Lever - Rmv Outside Mirror 80 - 200
- Engine Support T10359
- Engine/Transmission Jack V.A.G 1383 A
- Hose Clip Pliers V.A.G 1921
- Step Ladder VAS 5085
- Drip Tray for VAS 6100 VAS 6208
- Ring Spanner 7-Piece Set 3337
- Locking Pin T10060A
- Puller T10369
- Engine Bung Set VAS 6122
Procedure
Note. Assemble engine with transmission downward. During installation, cable ties must be installed at the same location. Collect escaping coolant in a clean container for disposal or reuse. Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.
| WARNING | There is a risk of injury because the fuel is under very high pressure. When removing the engine, the high pressure area of the fuel injection system is not opened. If the engine is removed and the high pressure area is opened for the following steps, the fuel pressure in the injection system must be reduced to a residual pressure before opening the high pressure area. |
Reduce fuel pressure in high pressure area. Refer to General Information .
| CAUTION | Risk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery. |
Remove luggage compartment floor covering.
Remove the rear lid trim panel if the cover for the battery negative pole it located underneath it. Refer to Removal and Installation .
Release retaining clips -arrows- and remove the negative post cover.
Scheme 875
Loosen the nut a few turns and remove battery terminal -arrow- on Ground (GND) cable from the battery post.
Scheme 876
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. |
Open the coolant reservoir cap.
Remove the bolts -arrows- and air guide.
Scheme 877
Note. Shown on the 2.0L engine.
Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.
Scheme 878
Remove the air guide hose -2-.
Remove the bolt -4- and the air filter housing.
Note. Ignore -3-.
Remove the bolts -arrows- and the air filter housing bracket.
Note. Shown on the 2.0L engine.
Remove both front wheels. Refer to Removal and Installation .
Remove the noise insulation. Refer to Removal and Installation .
Remove the left and right noise insulation -arrows-.
Scheme 879
Remove the frame for the noise insulation. Refer to Removal and Installation .
Remove the air guide pipe -1 and 2-.
Scheme 880
Disconnect the connector -2-.
Scheme 881
Remove the bolts -3-.
Disconnect the connector -2- from the Engine Coolant Temperature (ECT) sensor on radiator -G83-.
Scheme 882
Note. Collect escaping coolant in a clean container for disposal or reuse.
Place VAS 6208 under the engine.
Remove the coolant hose -1- by pulling the retaining clip out and letting the coolant drain.
Remove the coolant hose from the after-run coolant pump -V51- -arrow- and drain the remaining coolant.
Scheme 883
Remove the bolt -1-.
Scheme 884
Note. Ignore items -2, 3 and 4 and the arrow-.
Remove the bolts -1- and remove the fan shroud upward.
Note. Ignore -2 and 3-.
Loosen the hose clamp -2-.
Disconnect the electrical connectors -arrow- and free up the electrical wire.
Remove the bolt -4- and the air guide pipe.
Note. Ignore -1 and 3-.
Remove the upper coolant hose from the radiator -arrow-.
Scheme 885
Remove the bolts -arrows- on the rear side of the radiator.
Scheme 886
Remove the radiator downward.
| CAUTION | Risk of destroying 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. |
To release ribbed belt tension, rotate tensioner in direction of -arrow-.
Scheme 887
Remove ribbed belt and release tensioning device.
Note. Ignore the T10060 A.
| WARNING | Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen. |
| CAUTION | Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS . |
Remove the fuel hose -1- and free it up.
Scheme 888
Remove the hose -1-.
Release the Evaporative Emission (EVAP) canister -B arrow-, remove it upward -A arrow- and lay it aside.
Disconnect the coolant hoses -arrows- and move them to the side.
Scheme 889
Note. The installation location is shown with the engine removed.
Remove the air guide pipe bolt -arrow-.
Remove the air guide pipe; to do this, loosen the hose clamp -1-.
Press the release buttons and remove the air guide hose -2-.
Remove the coolant hose -1-.
Scheme 890
Remove the bolt -2-.
Remove the coolant hoses -1 and 2-.
Scheme 891
Remove the bolt -3-.
Note. Be careful of the GND wire -arrow- when installing.
Remove the heat shield -arrows-.
Scheme 892
Remove the coolant hoses from the heater heat exchanger -arrows-.
Scheme 893
From above, remove the nuts -arrows- on the front exhaust pipe connection to the turbocharger.
Scheme 894
Remove the vacuum hose from the brake booster -arrow-.
Scheme 895
Pry cover caps off windshield wiper arms with screwdriver.
Scheme 896
Loosen nuts -arrows- a few turns.
Position the T10369/1 on the windshield wiper arm -1- as illustrated.
Scheme 897
Mount the pressure piece -2- on the wiper axle.
Turn the screw -3- clockwise until the wiper arm is pulled off the wiper axle.
Remove nuts completely and remove wiper arms.
Remove gasket -1-.
Scheme 898
| CAUTION | The plenum chamber cover could be damaged. Coat the transition area between the windshield and plenum chamber cover -2- with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window. |
Remove plenum chamber cover -2- by carefully pulling cover out of retainer on windshield.
Free up engine wiring harness on the back of the plenum chamber bulkhead.
Remove Engine Control Module (ECM). Refer to Removal and Installation .
Scheme 899
Disconnect the engine wiring harness electrical connector -1- -arrow-.
Release engine wiring harness feed through -1- and remove upward -arrow-.
Scheme 900
Remove E-box cover by sliding both latches in direction of -arrow-.
Scheme 901
Open wiring router bracket -arrows-.
Scheme 902
Unclip electrical connector -1- from bracket and disconnect.
Scheme 903
Open wiring router bracket below.
Unclip engine wiring harness to engine control module from wiring router.
Place engine wiring harness with the ECM on the engine.
Secure the ECM against falling down.
Unclip electrical connector -2- from bracket and disconnect.
Remove the terminal 30 wire -arrow- at the engine compartment E-box and free it up.
Scheme 904
Note. To unclip spiral clip, use 80 - 200.
Metal Selector Relay Lever -B
Scheme 905
Remove the lock washer -arrow 1- from the transmission shift lever -A- and remove the shift cable.
Remove the lock washer -arrow 2- from the selector relay lever -B- and then remove the selector cable.
Plastic Selector Relay Lever
Scheme 906
Remove the lock washer -arrow 1- and the shift cable.
Press the retainer -arrow 2- down as far as the stop and remove the selector relay lever and cable retainer. Move it in the direction of operation.
Tie cables with cable bracket off to the side.
Remove the transmission support -A arrows-.
Scheme 907
Remove the clutch slave cylinder -B arrows-, move it to the side and secure it with wire. Do not open the line system.
| CAUTION | Do not press the clutch pedal when the clutch slave cylinder is removed. |
Cut off cable ties -arrow- for protective boot -3-.
Scheme 908
Disconnect the connector -2-.
Fold back protective boot and remove the battery positive wire from the starter solenoid.
Remove the GND wire nut -1-.
Remove upper starter bolt.
Vehicles with FWD
Scheme 909
Remove the right drive axle heat shield -arrows-.
Remove the left and right drive axles from the transmission flange shafts.
Remove GND wire -3-.
Scheme 910
Cut through the cable tie -arrow- for the protective boot.
Disconnect the connector -2-.
Fold back the protective boot -1- and remove the battery positive wire from the starter solenoid.
| CAUTION | Risk of destroying control module (Mechatronic) with static discharge. Do not touch contacts in transmission connector with hands. |
To discharge static electricity, touch vehicle ground with hand (without gloves).
Disconnect electrical connector -4- by turning twist lock counterclockwise.
Free up the wiring harnesses -arrows- and disengage the electrical connector -1- at the bracket.
Scheme 911
AWD Vehicles
Scheme 912
Remove the right drive axle heat shield from bevel box -arrows-.
Remove the left drive axle from the transmission flange.
Remove the right drive axle from the bevel box flange.
Raise the drive axles and secure them with a cable tie.
Note. Make sure the drive axle surface protection is not damaged.
Remove the left nut -1- if applicable.
Scheme 913
Remove the left nuts -arrows- for the control arm. Refer to Removal and Installation .
Scheme 914
Disengage the control arm from the transverse link.
Tilt the left suspension strut outward and support it with the extension 2024 A /1 as shown in the illustration.
Scheme 915
| WARNING | Loose support components could cause an accident. Secure the securing pin and transverse link with the securing pin -arrow- and nut -1-. |
Vehicles with S-Tronic Transmission 02E
Scheme 916
Remove the bolts -1- from the cable bracket -2-.
Remove locking washer -3- -arrow- and remove selector lever cable from transmission.
AWD Vehicles
Scheme 917
Mark position of flexible disc to bevel box flange for reinstallation.
Remove the driveshaft flexible disc bolts -arrows- from the bevel box while counter holding at the triangular flange with a lever.
Scheme 918
| CAUTION | The shaft seal -arrow- in the driveshaft flange could be damaged. Press driveshaft horizontally as far back and to right side of vehicle as possible. |
All Vehicles
Scheme 919
Remove the bolts -1 and 2- on the bracket for the oxygen sensor electrical connector under the underbody. Remove the cover.
Remove the bolt -3- and free up the electrical wire to the oxygen sensor.
Remove the connector coupling -arrow- from the bracket.
Scheme 920
Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and free it up.
Remove the rest of the nuts accessible from below that connect the front exhaust pipe to the turbocharger -arrows-.
Remove the bolts -arrows-, exhaust system bracket and cross brace.
Scheme 921
| CAUTION | Risk of damaging decoupling elements. Do not bent decoupling elements in front exhaust pipe more than 10°. |
Loosen the nuts -arrows- at the clamping sleeve and separate the exhaust system.
Scheme 922
Remove the front exhaust pipe with the catalytic converter and front muffler.
Remove bolts -1, 2, 3- and remove pendulum support.
Scheme 923
Disconnect the connector -1- from the oil level thermal sensor -G266-.
Scheme 924
Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.
Remove the air guide hose -arrows-.
Scheme 925
Loosen the subframe mount bolts -arrows- on the engine approximately two turns.
Loosen the subframe mount bolts -arrows- on the transmission approximately two turns.
Disconnect the Air Conditioning (A/C) compressor regulator valve -N280- -1- connector from the A/C compressor.
Scheme 926
| WARNING | Refrigerant can cause serious personal injury. Do not open the A/C refrigerant circuit. |
Remove the A/C compressor bolts -arrows-.
| CAUTION | Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses. |
Tie up the compressor with the refrigerant lines attached to the longitudinal member.
Attach the T10359 to the cylinder block with the bolt -1- to approximately 20 Nm.
Scheme 927
Note. The threaded hole in the bolt -1- serves to secure the after-run coolant pump -V51-.
Mount the V.A.G 1383 A on the T10359.
Slightly lift the engine/transmission subassembly.
Note. Use VAS 5085 to remove bolts for assembly mounting.
Remove the subframe bolts -arrows- on the engine.
Remove the subframe bolts -arrows- on the transmission.
Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. While lowering, carefully guide the engine/transmission assembly in order to prevent damages.
Pull the engine/transmission as far as possible to the front and left and slowly lower it.