Engine, Removing: Procedure

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WARNING:

Risk Of Vehicle Tipping Over With Engine Removed.

The luggage compartment must be empty to secure the vehicle.

NOTE:

Remove The Engine Without The Transmission Upward.

During installation, install all cable ties back at the same position.

In order to be able to turn the driveshaft on an AWD vehicle to remove it, release the electro-mechanical parking brake before disconnecting the battery.

Always seal off any open channels in the intake and exhaust tract with suitable plugs. For example, from the :VAS6122 .

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

-- Remove the left and right front wheels. Refer to VEHICLE ALIGNMENT .

-- Remove the left and right front wheel housing liners. Refer to Wheel Housing Liner .

-- Remove the noise insulation. Refer to Exterior Equipment .

-- Perform the service position. Refer to Body Front .

-- Remove the front exhaust pipe/front muffler. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Disconnect the connector -1- from the Mass Airflow Sensor - G70-.

Fig 1: Disconnecting Connector

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-- Loosen the air intake hose -2-.

-- Remove the air filter housing upward in direction of -arrows-.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the plenum chamber cover. Refer to Body Front .

-- Remove the left and right foam block -1- upward in direction of -arrows-.

Fig 2: Identifying Left And Right Foam Block

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-- Releases the retainer in direction of -arrow A- and open the cover in direction of -arrow B-.

Fig 3: Opening Terminal Box Cover

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-- Remove the nuts -1 through 3- for the wires.

Fig 4: Identifying Nuts

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-- Remove the connector -4- from the bracket and disconnect it.

-- Remove the bolt -5- and remove the wire junction from the tower brace -arrow-.

-- Release the retainers from the wheel housing side using a 5.5 mm open end wrench -1- and remove the wiring bushing -2- upward.

Fig 5: Release Retainers From Wheel Housing Side Using A 5.5 Mm Open End Wrench

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-- Wiring duct version 1: unlock the retainer and free up the wiring duct in direction of -arrow B- and pull the duct forward in direction of -arrow A-.

Fig 6: Freeing Up Wiring Duct By Releasing Retainer

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-- Wiring duct version 2: unlock the retainer in direction of -arrow-, free up the wiring harness and open the wiring duct -1-.

Fig 7: Freeing Up Wiring Harness And Open Wiring Duct

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-- Remove the nut -1- and tilt the washer fluid filler neck upward in direction of -arrow A-.

Fig 8: Identifying Filler Neck With Filler Tube From Washer Fluid Reservoir And Opening In Body

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-- Remove the filler neck -2- with the filler tube from the washer fluid reservoir and the opening in the body in direction of -arrow B-.

-- Remove the tower brace. Refer to TOWER BRACE .

-- Remove the bolts -arrows- and the engine compartment E-box cover.

Fig 9: Identifying E-Box Bolts & Cover

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-- Remove the nut -1- and free up the wire.

-- Release the retainers in direction of -A arrows- and remove the engine control module in direction of -arrow B-.

Fig 10: Engine Control Module (ECM)

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-- Disconnect the connectors -4- and remove the nut -3- for the electrical wire.

Fig 11: Disconnect Electrical Connectors

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-- Disconnect the connector -2- if applicable.

-- Release the retainers in direction of -arrow- and remove the relay panel with the fuse holder -1-.

-- Release the retainers in direction of -A arrows- and remove the cable grommet -1- upward in direction of -arrow B-.

Fig 12: Release Retainers And Removing Wiring Bushing

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-- Disengage the engine wiring harness at the engine compartment E-box and free it up.

-- Lay the wiring harness on the engine and secure the engine control module so that it cannot fall.

WARNING:

The Cooling System Is Under Pressure When The Engine Is Warm. 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 cloth and carefully opening it.

-- Open the coolant expansion tank cap.

-- Place the :VAS6208 under the engine.

-- Open the drain -1- and let the coolant drain out and then remove the connection -2- from the radiator.

Fig 13: Identifying Coolant Drain Plug

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-- Remove the left and right nuts -3- and remove the longitudinal braces -2-.

Fig 14: Identifying Carrier Left Brace Components

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-- Loosen the hose clamp -arrow-, remove the air duct hose and pivot it to the side.

Fig 15: Air Guide Hose, Hose Clamp

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-- Remove the nut -1- on the right longitudinal member and free up the ground wires.

Fig 16: Identifying Nut

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-- Remove the nut -2- for the bracket with the electrical wires on the right side of the vehicle.

-- Disconnect the radiator fan connector -1- by sliding the retainer back in direction of -arrow- and pressing the release downward.

Fig 17: Disconnecting Coolant Fan Electrical Connector -1- From Bracket

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-- Lay the wiring harness on the engine and secure it from falling down.

-- Disconnect the vacuum connection -2- from the plenum chamber bulkhead by remove the vacuum hose -3- on the back side in direction of -arrow-.

Fig 18: Disconnect Vacuum Connection

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-- Remove the nut -5-.

Fig 19: Identifying Coolant Hoses

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-- Remove the coolant hoses -1 through 4- and remove the plenum chamber bulkhead.

-- Remove the bolts -2 through 6-.

Fig 20: Engine To Transmission Bolts

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NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Pay attention to the spacer sleeve when removing or installing the engine -arrow-. The spacer sleeve must be inserted between the starter and the transmission.

Fig 21: Identifying Bolt & Spacer Sleeve

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-- Remove the coolant hose -2- and the permanent ventilation -1-.

Fig 22: Identifying Clamp

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-- Remove the permanent ventilation -1- and coolant hose -2- from the coolant reservoir.

Fig 23: Identifying Permanent Ventilation -1- And Coolant Hose -2-

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-- Loosen the hose clamps -arrows- and remove the air duct hose.

Fig 24: Air Intake Hose Components

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-- Disconnect and free up the connector for the Charge Air Pressure Sensor - G31- -1-.

-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

Vehicles With Hydraulic Power Steering:

Fig 25: Release Ribbed Belt Tension, Rotate Tensioner In Direction Arrow

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CAUTION:

Risk Of Destroying By Reversing The Running Direction On A Used Ribbed Belt.

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

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

-- Secure the tensioner with the :T40098 .

-- Remove the ribbed belt.

Vehicles With Electro-Mechanical Power Steering:

Fig 26: Rotating Belt Tensioner

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CAUTION:

Risk Of Destroying By Reversing The Running Direction On A Used Ribbed Belt.

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

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

-- Lock the tensioner using the :T10060A .

-- Remove the ribbed belt.

Continuation For All Vehicles:

CAUTION:

Risk Of Damaging The Refrigerant Lines And Hoses.

Do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the A/C compressor from the sub-assembly bracket and with the refrigerant hoses connected tie it up to the left side. Refer to A/C COMPRESSOR / A/C COMPRESSOR, REMOVING AND INSTALLING .

Vehicles With Hydraulic Power Steering:

-- Remove the power steering pump and with the hydraulic lines attached place on the longitudinal member. Refer to REMOVING & INSTALLING POWER STEERING PUMP, VEHICLES WITH DYNAMIC STEERING [CAEB, CPMA] / POWER STEERING PUMP, VEHICLES WITHOUT DYNAMIC STEERING [CAEB, CPMA] .

Continuation For All Vehicles:

Fig 27: Identifying Fuel Line

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-- Disconnect the supply hose -1- and return hose -2- for the fuel. Refer to CONNECTOR COUPLINGS, SEPARATING .

-- Support the transmission slightly with the :VAS6931 and mounted :T10337 .

Fig 28: Supporting Transmission With VAG 1383

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-- Remove the tunnel crossmember bolts -arrows-.

Fig 29: Identifying Bolts & Tunnel Crossmember

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Vehicles With Manual Transmission:

Fig 30: Lowering Transmission With VAG 1383

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-- Lower the transmission with the :VAS6931 to dimension -a-.

Dimension -a- = maximum 80 mm.

-- Disconnect and free up the connector -1- on the Back-Up Lamp Switch -F4- using the :T40138 .

Fig 31: Disconnecting Connector

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Vehicles With Dual-Clutch/Multitronic Transmissions:

Fig 32: Identifying ATF Return & Supply Pipe

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-- Remove the bolts -arrows- from the ATF lines.

Continuation For All Vehicles:

Fig 33: Unclip Wiring From Transmission

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-- Unclip the wire -A- from the transmission and disconnect the connector -C-.

-- Lift the transmission with the :VAS6931 and install the bolts -arrows- for the tunnel crossmember.

Fig 34: Identifying Bolts & Tunnel Crossmember

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-- Remove the lower cover -1- from the transmission in direction of -arrow-.

Fig 35: Identifying Transmission Lower Cover

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-- Remove the three flywheel bolts -arrow-. Turn the crankshaft an additional 120° in the direction of engine rotation.

Fig 36: Identifying Clutch Module First Bolt Installation Location

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-- Remove the screw on the starter -1- from the engine side.

Fig 37: Engine To Transmission Bolts

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-- Remove the starter from the transmission and leave it in the installation position.

-- Disconnect remaining engine to transmission connection bolts.

-- Support the transmission:

Version 1

Fig 38: Supporting Transmission (Version 1)

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-- Position the :10-222A with the :10-222A/8 on the left and right fender bolting edges as shown.

-- Connect the transmission and the spindle with the :10-222A/12 .

NOTE:

For Clarity, The Removed Engine Is Shown.

-- Lightly tension the :10-222A spindle.

Version 2

Fig 39: Supporting Transmission (Version 2)

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-- Position the :10-222A with the :10-222A/8 on the left and right fender bolting edges as shown.

-- Connect the transmission and spindles with the : T40132 , :VW771/40 and : 3368 as illustrated.

NOTE:

For Clarity, The Removed Engine Is Shown.

-- Lightly tension the :10-222A spindle.

All

Fig 40: Engine Lifted

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-- Engage the :2024A on the engine and on the :VAS6100 as illustrated.

WARNING:

Lifting Hooks And Pins On The Lifting Tackle Must Be Secured With Securing Pins.

-- Remove the left and right engine mount bolts -1-.

Fig 41: Disconnect Left Electrohydraulic Engine Mount Solenoid Valve

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-- Lift the engine until the engine mount is free.

-- Turn the :10-222A spindles.

CAUTION:

Risk Of Damaging The Hose And Line Connections As Well As The Engine Compartment.

Make sure all the hose and line connections between the engine, transmission, subframe and body have been disconnected.
Carefully lift and guide the engine out of the engine compartment.

-- Remove The Engine From The Transmission And Lift It Upward Out Of The Engine Compartment.