Engine, removing and installing: Removing

NOTE:

The engine is removed from underneath together with the transmission.
All cable ties which are opened or cut open when removing the engine must be replaced in the same position when installing the engine.
Secure all hose connections with hose clamps of the same type as those fitted at the factory.
V.A.G 1921 hose clip pliers are recommended when installing spring-type clips.
Make sure the connectors are correctly assigned; mark if necessary.

Obtain radio anti-theft code on vehicles with coded radio.
With the ignition switched off, disconnect the battery Ground (GND) strap.

Fig 1: Removing Right-Hand Cover Panels On Lock Carrier And Expansion Tank

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Remove right-hand cover panels -1- on lock carrier and -2- above expansion tank.

Fig 2: Removing Left-Hand Cover Panels On Lock Carrier And Battery

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Remove left-hand cover panels -1- on lock carrier and -2- above battery.

Fig 3: Removing Cover Panel Above Cylinder Head Cover And In Front Of Intake Manifold

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Remove cover panel above cylinder head cover and in front of intake manifold (if applicable).

Fig 4: Removing Intake Air Duct

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Remove intake air duct.
Disconnect secondary air intake hose -1- from air cleaner.

Fig 5: Identifying Air Hose, Connectors, Bolts & Mass Air Flow Sensor

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Disconnect air hose -2- from mass air flow sensor.
Disconnect connectors -3- from mass air flow sensor.
Remove bolts -4- and -5-, and remove air cleaner housing.
Remove battery.

Fig 6: Removing Battery Platform

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Remove battery platform (arrows).

Disconnect both selector cables at transmission as follows:

Fig 7: Pulling Collar (Toward Ball Joint) To Compress Spring, Then Turning Collar Clockwise To Lock In Position

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Mark position of both selector cables with waterproof felt-tip pen -1-.
Pull collar in direction of (arrow -2-) (toward ball joint) to compress spring, then turn collar clockwise (arrow -3-) to lock in position.
Disengage both selector cables.

Fig 8: Removing Bolts & Selector Cable Support Bracket From Transmission

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Remove bolts (arrows), remove selector cable support bracket from transmission and place to one side.
Remove both windshield wipers.
Detach rubber seal from plenum chamber.
Detach cover from plenum chamber and move clear toward windshield.

Fig 9: Opening Cable Duct On Left Side Of Engine Compartment

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Open cable duct on left side of engine compartment.
Disconnect connector in cable duct and move wiring clear.

Fig 10: Releasing Retainer Catch On Left Control Module Connector And Disconnecting Connector From Control Module

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Release retainer catch on left control module connector and disconnect connector from control module.
Release control module wiring harness as far as engine.

Fig 11: Disconnecting Connector Below Intake Manifold

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Disconnect connector below intake manifold.

Fig 12: Identifying Battery Ground Cable, Connector & Electrical Connections

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Unbolt Ground wire -1- on engine/transmission flange.
Disconnect wires -3- and -4- from starter.
Disconnect connector -2- and pull out of retainer.
Disengage wires from retainer on starter and move wires to one side.

Fig 13: Disconnecting Connector From Charge Air Pressure Sensor And Unclipping Wire From Charge Air Hose

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Disconnect connector from charge air pressure sensor and unclip wire from charge air hose.
Disconnect air hose from throttle valve control module.

Fig 14: Disconnecting Connector From Coolant Temperature Switch On Coolant Line

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Disconnect connector from coolant temperature switch on coolant line and move wiring clear.

Fig 15: Identifying Pull Fuel Supply Line And Fuel Return Line

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Disconnect fuel supply line -1- and fuel return line -2- at the connection point by pressing the release tabs.

NOTE: Watch color coding of connectors when reconnecting fuel supply and return lines.

WARNING:

Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Fig 16: Slackening Ribbed Belt

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Slacken ribbed belt by turning tensioning element in direction indicated (arrow).

NOTE: Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when refitted, this can result in breakage. When installing the belt, ensure it is correctly seated in the pulleys.

Remove ribbed belt.

Fig 17: Blocking Tensioner With 3090

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The tensioning element can be locked in position with a suitable punch (4.5 mm diameter, approx. 55 mm long). Connecting rod support 3090 can also be used.

Fig 18: Detaching Intake Air Hose Between Air Cleaner And Turbocharger

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Detach intake air hose between air cleaner and turbocharger as follows:
Disconnect connector at Wastegate Bypass Regulator Valve -N75-.
1- Connection at air cleaner
2- Detach pressure control valve for crankcase breather -8- from hose.

3- Disconnect vacuum hose for air recirculation valve at connection on cylinder head.
4- Detach hose from Wastegate Bypass Regulator Valve -N75- at intake air duct.
5- Detach hose from air recirculation valve at intake air duct.
6- Detach connection to active charcoal filter at non-return valve.

7- Detach connection between Wastegate Bypass Regulator Valve -N75- and pressure unit for charge air pressure control.
8- Detach air intake hose at connection on turbocharger and remove hose.
Remove cap from coolant expansion tank.

Fig 19: Disconnecting Vacuum Hose From Intake Manifold To T-Piece In Front Of Retainer In Plenum Chamber

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Disconnect vacuum hose from intake manifold to T-piece in front of retainer in plenum chamber.
Disconnect coolant hose to expansion tank in plenum chamber.

Fig 20: Identifying Coolant Pump Electrical Connector & Bolts

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Disconnect electrical connector at coolant pump.
Unbolt coolant pump from fan cowl; leave coolant hoses connected.
Remove both front wheels.

Fig 21: Unbolting Bracket For Headlight Range Control In Left Wheelhousing

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Unbolt bracket for headlight range control in left wheelhousing (top); detach retainer from suspension link and disconnect electrical connector.

Fig 22: Removing Noise Insulation Panels (Center, Left And Right)

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Remove noise insulation panels (center, left and right) (arrows).
Place drip tray V.A.G 1306 below engine.

Fig 23: Turning Drain Screw On Radiator

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Turn drain screw (arrow) on radiator counter-clockwise, if necessary install drain hose to connection.

Fig 24: Disconnecting Bottom Coolant Hose At Oil Cooler To Drain Off Remaining Coolant

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Disconnect bottom coolant hose at oil cooler (arrow) to drain off remaining coolant.

Fig 25: Identifying Connecting Line Bolts (Left)

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Unbolt connecting line between left....

Fig 26: Identifying Connecting Line Bolts & Right Charge Air Coolers

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... and right charge air coolers from longitudinal members and disconnect both hoses from charge air coolers.
Remove connecting line.

Fig 27: Disconnecting Connectors On Starter And Transmission

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Disconnect connectors on starter and transmission.
Remove positive connection on starter.

Fig 28: Removing Cooling Line From Transmission

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Remove cooling line from transmission.
Pull out retaining clip from coolant hose on radiator (bottom left) and disconnect coolant hose.
Open hose retainer on radiator (bottom left) and remove coolant hose completely.

Fig 29: Unbolting Pump Pulley (Brace Pulley With Hexagon Socket Wrench)

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Unbolt pump pulley (brace pulley with hexagon socket wrench).

Fig 30: Identifying Spring Clamp, Expansion Hose & Bracket

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Place clean container under pump.
Open spring clamp -3- on intake hose and disconnect hose.
Disconnect expansion hose -4-.

NOTE: On vehicles with pressure switch, first disconnect connector and remove switch.

Unbolt pump from bracket -1- and -2- (4 bolts).

Fig 31: Removing Coupling Link Nut From Stabilizer Bar

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Remove coupling link nut from stabilizer bar.
Remove upper nut on ball joint.

Fig 32: Installing Ball Joint Splitter

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Install ball joint splitter as shown in illustration and press out ball joint.

NOTE: To protect ball joint threads leave nut on a few turns.

Fig 33: Identifying Subframe Bolts, Steering Gear Bolts & Pendulum Support Bolts

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Remove bolts -1- for steering gear and bolts -2- for pendulum support.
Unbolt bracket for line to hydraulic fluid reservoir at steering gear (right).
Detach rubber mount at front exhaust pipe.
Place engine/transmission jack V.A.G 1383 A with universal support 1359/2 under subframe.

Remove subframe bolts -3- and -4-.
Lower subframe carefully.
Unbolt heat shield for right-hand drive axle.
Unbolt left and right drive axles from transmission flanges.

Move drive axles clear toward rear of vehicle and tie them to bolts provided for this purpose on subframe.
Remove front exhaust pipe. Refer to Exhaust system components, removing and installing .

NOTE: Do not bend the flexible connection on the front exhaust pipe more than necessary (not more than 10°).

Fig 34: Disconnecting Hoses And Connectors On Secondary Air Pump

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Disconnect hoses and connectors from secondary air pump.
Remove secondary air pump.

Vehicles with air conditioner:

Disconnect connector on A/C compressor and move wiring clear.

WARNING:

The air conditioner refrigerant circuit must not be opened.

Detach retainers for refrigerant hoses.

Fig 35: Unbolting A/C Compressor & Pressing Sliding Bushing Back Into Hole

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Unbolt A/C compressor -A-, lift clear and tie up on hood lock together with refrigerant hoses.

NOTE:

Before installing compressor press sliding bushing -B- back into hole.

Fig 36: Using Hose Clamp 3094 To Clamp Off Pressure Hose To Clutch Slave Cylinder

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Using hose clamp 3094, clamp off pressure hose -1- to clutch slave cylinder.
Pull out retainer toward the top (arrow) and disconnect pressure hose -1- from hose connector.
Disconnect connector from reversing light switch.

NOTE:

Do not depress clutch pedal.
The starter motor is removed in the illustration to give a clear picture.

Disengage wiring harness from retainers and place to one side.
Unbolt drive axle from transmission.

Fig 37: Locating Engine Carrier Bolts (Engine Side)

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Loosen engine/transmission assembly mount on engine side...

Fig 38: Locating Transmission Mounting Bracket Bolts

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and on transmission side (about 2 turns only). Do not remove the bolts completely.
Raise the vehicle.

Fig 39: Identifying Engine Bracket T10012 & Engine/Transmission Jack V.A.G. 1383A

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Bolt engine bracket T10012 to cylinder block with securing nut and bolt (M10 x 25/8.8). Tighten to about 20 Nm.
Install engine/transmission jack V.A.G 1383A to engine bracket and raise engine/transmission slightly.

Fig 40: Locating Engine Carrier Bolts (Engine Side)

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Unbolt engine/transmission mount on the engine side. (Use step ladder VAS 5085 for access to engine compartment from above.)

Fig 41: Locating Transmission Mounting Bracket Bolts

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Unbolt engine/transmission mount on the transmission side.
Carefully lower the engine/transmission assembly.

NOTE:

Check to make sure that all connections between engine and body have been detached.
The engine/transmission assembly must be carefully guided by a second mechanic while it is being lowered so as to avoid damaging the body panels.

Fig 42: Removing Bolts And From Bracket On Bevel Box

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Remove bolts -1- and -2- from bracket on bevel box.

NOTE: The bracket cannot be removed.

Fig 43: Removing/Installing Bolt & Small Cover Plate

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With transmission still in position, remove bolt -1- (wrench width = 10 mm) and pull out small cover plate -2- toward the top.

NOTE: The transmission is removed in the illustration to give a clear picture.

Fig 44: Removing Bolts On Engine/Transmission Flange

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Remove bolts -1- to -8- on engine/transmission flange.
Separate engine from transmission.