Engine, removing

NOTE:

The engine is removed toward the front with lock carrier removed.
All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
Drained coolant must be stored in a clean container for disposal or reuse.

Work procedure

On a vehicle with automatic transmission, shift selector lever to position "N".

CAUTION: Observe procedures for disconnecting battery → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 1: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

Open cap of coolant expansion tank.
Remove both front wheels.

Fig 2: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 3: Identifying Quick-Release Fasteners And Noise Insulation

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Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.

Fig 4: Removing Bracket For Noise Insulation

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Remove bracket for noise insulation - arrows -.

Fig 5: Removing Air Guides From In Front Of Charge Air Coolers At Left/Right

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Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Remove air guides from in front of charge air coolers at left and right - arrows -.

Fig 6: Opening/Closing Drain Plug From Lower Left Coolant Hose

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Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
Open drain plug - arrow - from lower left coolant hose and drain coolant.

Fig 7: Disconnecting Lower Coolant Hose From Radiator

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Disconnect lower coolant hose from radiator - arrow -.

Fig 8: Identifying Air Duct Hose & Bracket

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Remove air duct hose - 1 - to bottom of left charge air cooler.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Unhook refrigerant line from bracket - 2 -.

Fig 9: Removing Air Duct Hoses

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Remove air duct hose - 1 - to turbocharger at bottom right.
Remove air duct hose - 2 - to charge air cooler at lock carrier.

Fig 10: Disconnecting Hydraulic Hoses

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Clamp off hydraulic hoses to power steering system cooling coil using Hose Clamps Up to 25 mm dia. 3094.
Place old oil collecting and extracting device V.A.G 1782 underneath.
Disconnect hydraulic hoses - arrows -.

Fig 11: Disconnecting ATF Lines & ATF Line Bracket

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Vehicles with automatic transmission:

NOTE:

Observe the rules of cleanliness for working on automatic transmissions →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.

Place old oil collecting and extracting device V.A.G 1782 underneath.
Disconnect ATF lines - 2 and 3 - at separating point.
Remove ATF line bracket - 1 - on engine.

All:

Fig 12: Removing Engine Cover

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Remove engine cover - arrows -.

Fig 13: Removing Bolts & Air Duct

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Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.

Fig 14: Removing Top Coolant Hose From Radiator & Disconnecting Connectors For Left/Right Airbag Sensor

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Disconnect coolant hose - 1 - at top of radiator.
Disconnect electrical harness connector - 2 - for left and right airbag sensors on lock carrier.

Fig 15: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle

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Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.

Fig 16: Removing Electrical Harness Connectors From Bracket

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Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
Free up electrical wiring.

Fig 17: Separating Left/Right Electrical Connectors Of Horns

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Separate left and right electrical connectors - 3 - of horns - 2 -.

NOTE:

Ignore - 1 -.

Fig 18: Removing Bumper

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Remove bumper - arrows -.

Fig 19: Removing Left/Right Air Guides At Radiator

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Remove left and right air guides at radiator - arrows -.

Fig 20: Identifying Outside Air Temperature Sensor G17, Bolts & High Pressure Sensor G65 Electrical Harness Connector

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Unclip Outside Air Temperature Sensor G17 - 2 - from bracket.
Remove bolts - 3 - and - 4 - and remove power steering system cooling coil.
Disconnect electrical harness connector - 1 - at High Pressure Sensor G65.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Remove bolts - arrows - for condenser.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that lines and hoses are not stretched, kinked or bent.

Pivot condenser downward with lines connected.

Fig 21: Removing Bolts At Left/Right Side Of Bumper

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Remove bolts - arrows - at left and right side of bumper.
Unhook cable for hood release at lock.
Pull off hood seal from lock carrier and fender edges.

Fig 22: Removing Bolts At Left/Right Impact Absorbers

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Remove bolts - arrows - at left and right impact absorbers.

NOTE:

A second technician is required to remove lock carrier.

Remove lock carrier and set aside so it cannot topple.

NOTE:

Before removing ribbed belt, mark turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the belt under operating conditions.

Fig 23: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt

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Pivot belt tensioner for ribbed belt in direction of - arrow - to relieve tension on ribbed belt.
Secure tensioning element using Locking Tool T40098.
Remove ribbed belt.

Fig 24: Disconnecting Connector For Oil Level Thermal Sensor -G266-

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Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor G266.

Fig 25: Removing Bracket For Refrigerant Line On Oil Pan

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Remove bracket for refrigerant line on oil pan - arrow -.

Fig 26: Separating Connector For Wiring To Air Conditioning Compressor Clutch Solenoid

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Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

CAUTION: The air conditioning refrigerant circuit must not be opened.

Remove air conditioning compressor from bracket - arrows -.

NOTE:

To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Hang up air conditioning compressor and condenser with attached lines on right side of vehicle.

Fig 27: Unfastening Ground (GND) Cable, Disconnecting Vacuum Line To Brake Booster At Bulkhead & EVAP Hose

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Unfasten Ground (GND) cable - 1 -.
Disconnect vacuum line to brake booster at bulkhead - 2 -.
Disconnect EVAP hose - 3 -.

Fig 28: Removing Coolant Hoses And Unfastening Coolant Expansion Tank

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Remove coolant hoses - 1 and 2 - and unfasten coolant expansion tank - arrow -.
Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Fig 29: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left Charge Air Hose

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Separate electrical connector from Charge Air Pressure Sensor G31 - 1 -.
Remove left charge air hose - 2 -.

Fig 30: Removing Right Charge Air Hose

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Remove right charge air hose - 1 -.

Fig 31: Identifying Oxygen Sensor Electrical Connectors

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Pull electrical connector - 1 - for Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) G130 and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) Z29 (brown connector) out from retainer
Pull electrical connector - 2 - for Heated Oxygen Sensor (HO2S) G39 and Oxygen Sensor (O2S) Heater Z19 (black connector) out from retainer

CAUTION: Before opening a component of the high-pressure section, the fuel pressure must be released. Pay absolute attention to the procedure on → 24 - MULTIPORT FUEL INJECTION (MFI) .

Fig 32: Disconnecting Fuel Line

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Disconnect fuel line - arrow - (catch escaping fuel and plug open lines immediately).
Disconnect coolant hoses to heater core on rear of engine.
Remove windshield wiper arms.
Remove cowl.

Fig 33: Removing Screws And Cover From E-Box In Plenum Chamber

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Remove cover for E-Box in plenum chamber, by removing bolts - arrows -.

Fig 34: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623

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Carefully pry off retainer bar with a screwdriver - arrow -.

Fig 35: Removing Electrical Cable & E-Box Electrical Connectors

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Remove electrical cable - 1 -.
Disconnect electrical connectors - 2 to 4 - in E-box.

Fig 36: Unclipping Fuse Carrier

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Unclip fuse carrier - arrows -.
Free up cable and lay it aside on engine with Engine Control Module (ECM) J623 connected.

Fig 37: Removing Threaded Connections

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Remove threaded connections - 1 - of power steering pump through holes in belt pulley.

Fig 38: Removing Threaded Connection On Backside Of Power Steering Pump

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Remove threaded connection - arrow - on backside of power steering pump.

Fig 39: Disconnecting Connector & Separating Intake Hose

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Disconnect connector - 1 and 2 - and free up cable.
Separate intake hose - 3 - for air filter/turbocharger.

Fig 40: Disconnecting Electrical Harness Connector At Mass Air Flow (MAF) Sensor G70

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Disconnect electrical harness connector - 1 - at Mass Air Flow (MAF) Sensor G70.
Free up wiring harness on air filter housing and remove air filter housing - arrow -.

Fig 41: Removing Ground (GND) Strap From Right Longitudinal Member

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Remove Ground (GND) strap - arrow - from right longitudinal member.

Fig 42: Removing Heat Shield For Right Drive Axle

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Remove heat shield - 1 - for right drive axle.

Fig 43: Locating Clamping Sleeve

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NOTE:

Exhaust system decoupling element must not be bent more than 10 ° , otherwise it may be damaged.

Loosen clamping sleeve - arrow - and push it rearward.

Fig 44: Separating Front Exhaust Pipe/Catalytic Converter

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Separate front exhaust pipe/catalytic converter - arrows -.
Remove bolt - 1 - at bracket for front exhaust pipe and remove front exhaust pipe.

Fig 45: Disconnecting Connector From Back-Up Light Switch F4 And Free Up Cable To Wiring Harness

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Disconnect connector - arrow - from Back-Up Light Switch F4 and free up cable to wiring harness.

Fig 46: Identifying Engine/Transmission Threaded Connections

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Disconnect accessible engine/transmission threaded connections - 1 to 3 - and - 7 to 11 - from below.

Fig 47: Removing Starter

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Remove starter and pivot it aside.
Disconnect electrical connector - 3 -.
Remove nut - 1 - for clamp.
Remove nut - 2 - and remove electrical wiring.

Remove starter.

Fig 48: Identifying Threaded Connections & Locating Sleeves

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Mark installed position of threaded connections - 1 - and locating sleeves - 2 - on lower left and right engine mounts.

NOTE:

Depending on engine version, different fastening holes are utilized.

Remove nuts - 1 - at bottom on left and right engine mounts.

Fig 49: Locating Upper Nut On Left Engine Mount

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Loosen upper nut - arrow - on left engine mount several turns.

Fig 50: Hooking Engine Sling 2024 A Onto Engine And Onto Workshop Crane VAS 6100

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Hook engine sling 2024 A onto engine and onto workshop crane VAS 6100 as shown in the illustration.

NOTE:

To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.

CAUTION: Lifting hooks and alignment pins on the engine sling must be secured with securing pins.

Remove last engine/transmission connecting bolt.

NOTE:

Verify that all hose and line connections between engine and body have been disconnected.

Lift engine until engine mount studs are free.
Lift floor jack until transmission is supported.
Pull engine off from transmission and lift it forward and out of engine compartment.