Engine, Removing

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Special tools and workshop equipment required

Engine Sling 2024A
Engine Support Bridge 10-222A
Engine/Gearbox Support Shackle (2 pc.) 10-222A/12
Pry Lever 80-200
Engine and Gearbox Jack VAS6931
Shop Crane VAS6100
Engine Bung Set VAS6122
Shop Crane - Drip Tray VAS6208
Hose Clip Pliers VAS6362
Locking Pin T10060A
Engine/Gearbox Jack - Gearbox Support T10337
Belt Tensioner Locking Tool T40098
Reversing Light Switch Connector Release Tool T40138

Procedure

WARNING:

Risk of vehicle tipping over with engine removed.

Secure vehicle. Luggage compartment must be empty for this.

NOTE:

Remove the engine without the transmission upward.

Collect escaping coolant in a clean container for disposal or reuse.

When installing, bring all cable ties back to same positions.

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 Engine Bung Set VAS6122.

CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

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

-- Remove the left and right front wheels.

-- Remove the left and right front wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Perform a service position. Refer to SERVICE POSITION, PERFORMING AND RESETTING .

-- 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-.

-- Loosen the air intake hose -2-.

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

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-- Remove the engine cover in direction of -arrows-.

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-- Remove the plenum chamber cover. Refer to OVERVIEW - BULKHEAD .

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

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

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

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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 in direction of -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.

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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-.

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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-.

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

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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 bolts -1- and nuts -2- and the tower brace -3-.

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-- Remove the bolts -arrows- and the engine compartment E-box 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 (ECM) in direction of -arrow B-.

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

-- Disconnect the connector -2- if applicable.

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

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

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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 ECM so that it cannot fall.

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.

-- Open the coolant reservoir cap.

-- Place the Shop Crane - Drip Tray VAS6208 under engine.

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

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

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-- Loosen the hose clamp -arrow-, pull off the air guide hose and move it to the side.

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-- Remove the nut -1- on the right longitudinal member and free up the Ground (GND) wires.

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

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

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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-.

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-- Remove the nut -5-.

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

-- Remove the bolts -2 through 6-.

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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 with removing or installing the engine -arrow-. The spacer sleeve must be inserted between the starter and the transmission.

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

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

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

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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

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CAUTION:

Risk of damage 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-.

-- Secure the tensioner with the Belt Tensioner Locking Tool T40098.

-- Remove the ribbed belt.

Vehicles with Electro-Mechanical Power Steering

CAUTION:

Risk of damage 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-.

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-- Secure the tensioning system using Locking Pin T10060A.

-- Remove the ribbed belt.

Continuation for All Vehicles

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-- Disconnect solenoid clutch electrical connector -1- on Air Conditioning (A/C) compressor.

WARNING:

Refrigerant can cause serious personal injury.

Do not open the A/C system refrigerant circuit.

-- Remove the bolts -arrows- on the A/C compressor.

CAUTION:

Danger of causing damage to the refrigerant lines and hoses.

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

-- Tie up the A/C compressor to the longitudinal member with the refrigerant hoses still connected.

Vehicles with Hydraulic Power Steering

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NOTE:

The power steering pump hydraulic lines remain connected.

-- Remove the bolts -1- from the front through the belt pulley and then remove the bolt -2- from the back.

NOTE:

The power steering pump is shown in the illustration without the belt pulley and without the hydraulic lines (See the illustration above).

-- Remove the power steering pump with the hydraulic lines connected to the longitudinal.

Continuation for All Vehicles

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CAUTION:

Follow the guidelines for cleanliness when working on the fuel supply system.

-- Disconnect the fuel supply hose -1- and return hose -2-.

-- Support the transmission with the Engine/Gearbox Jack VAG1383A and Engine/Gearbox Jack - Gearbox Support T10337.

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-- Remove the bolts from the tunnel crossmember -arrows-.

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Vehicles with A Manual Transmission

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-- Lower the transmission to dimension -a- using the Engine/Gearbox Jack VAG1383A.

Dimension -a- = maximum 80 mm.

-- Disconnect and free up the connector -1- on the Back-Up Lamp Switch -F4- using the Reversing Light Switch Connector Release Tool T40138.

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Vehicles with S tronic/Multitronic Transmissions

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

NOTE:

Ignore items -1 and 2-.

Continuation for All Vehicles

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

-- Raise the transmission using the Engine/Gearbox Jack VAG1383A and install the tunnel crossmember bolts -arrows-.

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

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

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

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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

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-- Position the Engine Support Bridge 10-222A with the Engine Support Bridge - Engine Support Feet 10-222A/8 on the left and right suspension strut towers as illustrated.

-- Connect the transmission and the spindle with the Engine/Gearbox Support Shackle (2 pc.) 10-222A/12.

NOTE:

To improve clarity, the removed engine is shown.

-- Lightly tension the Engine Support Bridge 10-222A spindle.

Version 2

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-- Position the Engine Support Bridge 10-222A with the Engine Support Bridge - Engine Support Feet 10-222A/8 on the left and right suspension strut towers as illustrated.

-- Connect the transmission and spindles with the Puller - Sender Wheel 1 T40132, Slide Hammer Set - Adapter 40 VW771/40 and Lifting Eyebolt 3368 as illustrated.

NOTE:

To improve clarity, the removed engine is shown.

-- Lightly tension the Engine Support Bridge 10-222A spindle.

All

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-- Engage the Engine Sling 2024A on the engine and on the Shop Crane VAS6100 as illustrated.

WARNING:

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

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

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NOTE:

Ignore -arrow-.

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

-- Turn the Engine Support Bridge 10-222A spindles.

CAUTION:

Risk of damaging hose and wiring connections as well as engine compartment.

Make sure all the hoses and lines 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 out of the engine compartment.