Engine, Removing

WARNING: This page is about a different variant/trim than selected.

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.

Fig 1: Battery Cover

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-- Loosen the nut a few turns and remove battery terminal -arrow- on Ground (GND) cable from the battery post.

Fig 2: Remove Ground Wire Terminal Clamp

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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.

Fig 3: Identifying Bolts -Arrows- And Air Guide

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NOTE:

Shown on the 2.0L engine.

-- Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Fig 4: Air Flow Housing, Electrical Connector And Guide Hose

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-- 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.

Fig 5: Air Filter Housing Bracket

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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-.

Fig 6: Identifying Noise Insulation Frame

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-- Remove the frame for the noise insulation. Refer to Removal and Installation .

-- Remove the air guide pipe -1 and 2-.

Fig 7: Air Cooler Air Duct

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-- Disconnect the connector -2-.

Fig 8: Fan Shroud Bolts And Electrical Connector

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-- Remove the bolts -3-.

-- Disconnect the connector -2- from the Engine Coolant Temperature (ECT) sensor on radiator -G83-.

Fig 9: ECT Electrical Connector

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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.

Fig 10: Coolant Hose After-Run Coolant Pump V51

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-- Remove the bolt -1-.

Fig 11: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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NOTE:

Ignore items -2, 3 and 4 and the arrow-.

-- Remove the bolts -1- and remove the fan shroud upward.

Fig 12: Fan Shroud Bolts And Electrical Connector

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NOTE:

Ignore -2 and 3-.

-- Loosen the hose clamp -2-.

Fig 13: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- 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-.

Fig 14: Identifying Radiator Upper Coolant

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-- Remove the bolts -arrows- on the rear side of the radiator.

Fig 15: Identifying Radiator Bolts

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-- 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-.

Fig 16: Rotating Tensioner

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-- 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.

Fig 17: Identifying Fuel Hose

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-- Remove the hose -1-.

Fig 18: Locating Fuel Supply Line

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-- 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.

Fig 19: Coolant Hoses

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NOTE:

The installation location is shown with the engine removed.

Fig 20: Locating Air Guide Pipe Bolt

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-- 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-.

Fig 21: Locating Coolant Hose Bolts

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-- Remove the bolt -2-.

-- Remove the coolant hoses -1 and 2-.

Fig 22: Identifying Coolant Hoses

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-- Remove the bolt -3-.

NOTE:

Be careful of the GND wire -arrow- when installing.

-- Remove the heat shield -arrows-.

Fig 23: Turbocharger And Heatshield

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-- Remove the coolant hoses from the heater heat exchanger -arrows-.

Fig 24: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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-- From above, remove the nuts -arrows- on the front exhaust pipe connection to the turbocharger.

Fig 25: Front Exhaust Pipe/Turbocharger Nuts

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-- Remove the vacuum hose from the brake booster -arrow-.

Fig 26: Brake Booster Vacuum Hose

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-- Pry cover caps off windshield wiper arms with screwdriver.

Fig 27: Wiper Arm Nuts

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-- Loosen nuts -arrows- a few turns.

-- Position the T10369/1 on the windshield wiper arm -1- as illustrated.

Fig 28: Identifying Windshield Wiper Arm With Puller T10369/1

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-- 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-.

Fig 29: Rubber Seal & Plenum Chamber Cover

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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 .

Fig 30: Disconnecting Engine Wiring Harness Electrical Connector

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-- Disconnect the engine wiring harness electrical connector -1- -arrow-.

-- Release engine wiring harness feed through -1- and remove upward -arrow-.

Fig 31: Release Engine Wiring Harness Feed

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-- Remove E-box cover by sliding both latches in direction of -arrow-.

Fig 32: Identifying E-Box Cover And Latches

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-- Open wiring router bracket -arrows-.

Fig 33: Opening Wiring Router Bracket

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-- Unclip electrical connector -1- from bracket and disconnect.

Fig 34: Unclip Electrical Connector

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-- 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.

Fig 35: Locating Engine Compartment E-Box Nut

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NOTE:

To unclip spiral clip, use 80 - 200.

Fig 36: Free Electrical Wiring Up To Generator Using Pry Lever - Rmv Outside Mirror 80-200

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Metal Selector Relay Lever -B- :

Fig 37: Identifying Removal/Installation Of Metal Relay Lever

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-- 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:

Fig 38: Identifying Selector Relay Lever

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-- 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-.

Fig 39: Identifying Transmission Support And Slave Cylinder

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-- 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-.

Fig 40: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

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-- 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:

Fig 41: Identifying Right Drive Axle Heat Shield And Bolts

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-- Remove the right drive axle heat shield -arrows-.

-- Remove the left and right drive axles from the transmission flange shafts.

-- Remove GND wire -3-.

Fig 42: Disconnect The Ground (Gnd) Wire -3-.

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-- 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.

Fig 43: Identifying Wiring Harnesses And Connector On Hot Side Charge Air Pipe

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AWD Vehicles:

Fig 44: Identifying Right Drive Axle Heat Shield

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-- 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.

Fig 45: Electrical Connector On Left Front Level Control System Sensor G78

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-- Remove the left nuts -arrows- for the control arm. Refer to Removal and Installation .

Fig 46: Ball Joint Lower Nuts

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-- 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.

Fig 47: Supporting Right Suspension Strut With Tool 2024 A/1

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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:

Fig 48: Elector Lever Cable Bracket Bolts And Locking Washer

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-- Remove the bolts -1- from the cable bracket -2-.

-- Remove locking washer -3- -arrow- and remove selector lever cable from transmission.

AWD Vehicles:

Fig 49: Driveshaft Flexible Disc

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-- 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.

Fig 50: Identifying Driveshaft Flange Shaft Seal

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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:

Fig 51: Identifying Retaining Screws And Cover

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-- 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.

Fig 52: Electrical Connector -arrow-

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-- 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-.

Fig 53: Front Exhaust Pipe/Turbocharger Nuts

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-- Remove the bolts -arrows-, exhaust system bracket and cross brace.

Fig 54: Crossbrace Bolts -Arrows-

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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.

Fig 55: Clamping Sleeve -Arrows-

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-- Remove the front exhaust pipe with the catalytic converter and front muffler.

-- Remove bolts -1, 2, 3- and remove pendulum support.

Fig 56: Identifying Pendulum Support & Bolts

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-- Disconnect the connector -1- from the oil level thermal sensor -G266-.

Fig 57: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

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-- Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.

-- Remove the air guide hose -arrows-.

Fig 58: Air Guide Hose

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-- Loosen the subframe mount bolts -arrows- on the engine approximately two turns.

Fig 59: Identifying Engine Mount To Engine Mount Bracket Bolts

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-- Loosen the subframe mount bolts -arrows- on the transmission approximately two turns.

Fig 60: Identifying Engine Mount To Engine Mount Bracket Bolts

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-- Disconnect the Air Conditioning (A/C) compressor regulator valve -N280- -1- connector from the A/C compressor.

Fig 61: A/C Compressor Bolts And Solenoid Clutch Electrical Connector

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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.

Fig 62: Engine Bracket T10359 And Cylinder Block

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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.

Fig 63: Identifying Engine Mount To Engine Mount Bracket Bolts

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-- Remove the subframe bolts -arrows- on the transmission.

Fig 64: Identifying Engine Mount To Engine Mount Bracket Bolts

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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.