Engine, Removing, Vehicle With Starter Generator

Special tools and workshop equipment required 

• Engine Support Bridge: 10-222A 
• Engine Support Bridge - Spindle: 10-222A/11 
• Engine Sling: 2024A 
• Shop Crane: VAS6100 
• Engine Support Bridge Adapter: 3147 
• Ring Wrench 7-Piece Set: 3337 
• Torque Wrench 1332 Insert - Ring Wrench - 16mm: VAG1332/14 
• Shop Crane: VAS6100 
• Engine Bung Set: VAS6122 
• Coolant Collection System: VAS5014  or Shop Crane - Drip Tray: VAS6208 
• Hose Clip Pliers: VAS6362 
• Torque Wrench Adapter: VAS6948 
• Locking Pin: T10060A 
• Engine Support - Supplement Kit - Adapter: T40093/6  from the Engine Support - Supplement Kit: T40093B 
• Wrench - 21mm: T40263 
• Adapter: T40314 
• Protective Eyewear
• Safety Gloves

Procedure 

• Remove the engine upward without the transmission.
• During installation, all cable ties must be installed at the same location.

-- Observe the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

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

-- Engage the 4th gear on versions with a manual transmission.

-- Carefully pull the engine cover off the retaining pins one after the other in direction of -arrows-. Do not remove the engine cover on one side or in a jerking manner.

-- Open the cover -1- for the coolant expansion tank by releasing the catch -arrow-.

-- Remove the front wheels. Refer to WHEELS AND TIRES .

-- Remove the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

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

-- Remove the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Remove the lock carrier cover, right and left air intake grille as well as the bumper cover end plate. Refer to OVERVIEW - BUMPER COVER .

-- Remove the bolts -arrows- and then remove the air guides -1 and 2-.

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-- Disconnect the connector -2- for the Mass Airflow Sensor -G70-.

-- Remove the vacuum hose -3-.

-- Loosen the hose clamp -4- and remove the air duct hose.

-- Pull the air filter housing -1- upward.

-- Release the latch in direction of -arrow B- and open the E-box -1- in direction of -arrow A-.

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-- Remove the nut -2- and free up the B+ wire.

-- Free up the upper wiring duct.

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

-- Secure the tensioner using the : T10060A  .

-- Remove the ribbed belt.

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

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-- Loosen the screw-type clamp -2- and remove the air duct pipe from the Throttle Valve Control Module -J338-.

-- Loosen the left front wheel housing liner in the front area and push slightly toward the rear. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Loosen the hose clamp -1- and remove the air duct hose and remove downward.

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-- Place the container of the : VAS5014  or the : VAS6208  underneath.

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-- Open the drain plug -1- on the connection and drain the coolant.

-- Remove the bolts -arrows- and push the wiring duct downward -1-. There are different versions.

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-- Remove the A/C compressor from the bracket. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Loosen the hose clamp -arrow- and remove the air duct hose at the right from the turbocharger.

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-- Remove the connector -2- from the bracket and disconnect it.

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-- Release the catches in direction of -arrows- and free up the wiring duct -1-.

-- Free up the wiring harness to the engine.

-- Remove the nut -arrow- and free up the ground wire.

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

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-- Release the catches -arrow- and remove the air ducts -1 and 3-.

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-- Unclip the air duct -2-.

-- Remove the upper air duct -arrow-.

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-- Remove the left and right bolt -2- and push the radiator bracket -1- with the bolt toward the front in direction of -arrow-.

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-- Release the left and right catches in direction of -arrows- and remove the retaining pin -1- for the radiator upward.

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-- Push the radiator slightly forward.

-- Remove the bolts -arrows- and remove the right drive axle heat shield.

-- Remove the left and right drive axles from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the steering intermediate shaft from the steering gear and push together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Remove the nuts -arrows- from the front muffler.

-- Remove the bolts -arrows-. (Shown on the right)

-- Loosen the clamping sleeve -arrows- and push toward the rear.

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-- Remove the front muffler.

-- Remove the bolt -arrow- from the particulate filter bracket.

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-- Remove the bolt -arrow- from the catalytic converter bracket.

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-- Remove the catalytic converter nut -2-. (The nuts -1- will be removed later.)

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

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-- To loosen the bolts for the flywheel, counterhold the crankshaft using the : T40263  and : T40314  .

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-- Turn the crankshaft an additional 120° respectively in the direction of engine rotation -arrow-.

-- Remove the three bolts -arrow- for the flywheel -1-.

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Vehicle with Manual Transmission: 

-- Loosen the bolt -1- using the : VAG1332/14  and : VAS6948  .

-- Remove the bolts -6 through 10- that attach the engine to the transmission.

Vehicle with Dual-Clutch Transmission: 

-- Loosen the bolt -1- using the : VAG1332/14  and : VAS6948  .

-- Remove the bolts -6 through 10- that attach the engine to the transmission.

Continuation for All Vehicles: 

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-- Remove the left and right bolt -2- from the engine mount.

-- Free up and disconnect the connector -1- for the Exhaust Gas Temperature Sensor 4 -G648-.

-- Disconnect the connector -3-.

-- Remove the bolt -1-, and free up the Differential Pressure Sensor -G505-.

-- Disconnect the connector -1- from the Vacuum Sensor -G608- -2-.

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-- Remove the nuts -arrows- and push the particulate filter -1- to the rear.

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-- Free up the wires on the heat shield -1-.

-- Remove the nuts -arrows- and bolts -2- and remove the heat shield. (Shown with the particulate filter removed).

-- Remove the connector -2- for the Exhaust Gas Temperature Sensor 3 -G495- from the bracket and disconnect.

-- Open the clip -3- and free up the vacuum hose.

-- Remove the bolt -1-, and push aside the bracket. There are different versions.

-- Remove the particulate filter.

-- Disconnect the connector -2- for the Oxygen Sensor After Catalytic Converter -G130- -1- and free up the wires.

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-- Disconnect the connector -1- for the Heated Oxygen Sensor -G39- -2-. (There are different installation positions.)

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-- Free up the wiring harness on the engine and move to the side.

-- Remove the nuts -1- and the catalytic converter toward the rear upward.

-- Disconnect the fuel hose -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Loosen the hose clamps to disconnect the hose for the EVAP system -2-.

-- Lift the clamp -arrow- and remove the coolant hose.

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-- Lift up the clamps -arrows- and remove and free up the coolant hoses.

-- Disconnect the connector -1- for the Engine Coolant Level Warning Switch -F66-.

-- Remove the bolt -2- and remove the coolant expansion tank -3-.

-- Lift the clamp -1 and 3-, and remove the coolant hoses.

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Vehicle with Dual-Clutch Transmission: 

-- Lift the clamp -2- and remove the coolant hose.

-- Loosen the hose clamp -arrow- on the left coolant pipe and remove the coolant hose.

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Vehicle with Manual Transmission: 

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-- Lift the clamp -1- and remove the coolant hose.

Continuation for All Vehicles: 

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-- Remove the connector -2- from the bracket and disconnect it.

-- Disconnect the connector -1- from the engine control module.

-- Free up the wiring harness and place it on the engine.

-- Disconnect the connector -arrow- for the starter generator.

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-- Release the retainer in direction of -arrow- and remove the vacuum hose -1-.

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Vehicle with Manual Transmission: 

-- Remove -2 to 5- that are accessible from above that connect the engine to the transmission.

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

Vehicle with Dual-Clutch Transmission: 

-- Remove the bolts -2 to 5- that are accessible from above that connect the engine to the transmission.

Continuation for All Vehicles: 

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-- Position the : 10-222A  with : 10-222A/22  on the left and right fender bolting edges as shown. (Shown with the engine removed.)

-- Connect the transmission and : 10-222A/11  with the : 3147  .

-- Slightly pre-tension the transmission using the spindle.

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

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

-- Turn the : 10-222A/11  .

-- Remove the engine from the transmission and lift it upward out of the engine compartment.