Engine, Removing

Special tools and workshop equipment required 

• Pry Lever:80-200 
• Engine Sling - Engine Bracket:2024A/1  for the Engine Sling:2024A 
• Securing element from the Transmission Support:3282 
• Engine Bung Set:VAS6122 
• Coolant Collection System:VAS5014  or Shop Crane - Drip Tray:VAS6208 
• Hose Clip Pliers:VAS6362 
• Engine and Gearbox Jack:VAS6931 
• Support Bridge:T10323  for AWD vehicles
• Engine/Gearbox Jack - Engine Support:T10359A 
• Commercially available Step Ladder
• Protective Eyewear
• Safety Gloves

Procedure 

• The engine with transmission is removed downward.
• During installation, all cable ties must be installed at the same location.

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Loosen the clamps -1 and 2- and remove the air guide hose.

-- Seal the open lines and connections with clean plugs from the :VAS6122  .

-- Place the :VAS5014  or :VAS6208  underneath.

-- Lift the clamp -2-, remove the lower right coolant hose from the radiator and drain the coolant.

-- Loosen the coolant hose -arrow-, remove the coolant hose and hold it toward the rear and let the coolant drain.

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-- Remove the bolts -1 and 3-.

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-- Release the catch in direction of -arrow- and remove the cover -2-.

-- Carefully pull the engine cover off the retaining pins one after the other in direction of -arrows-. Do not pull sharply on the engine cover or pull it to one side.

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-- Free up the coolant hose -2-.

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-- Open the catches in direction of -arrows- and remove the upper air duct -1-.

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

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-- Disconnect the vacuum hose -1-.

-- Loosen the hose clamp -3- and remove the air duct hose.

-- Remove the air filter housing -4- upward from the bracket.

-- Remove the bolt -arrow- on the left and right.

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-- Unclip and remove the lower section -1- of the air duct.

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Disconnect the vacuum hose -2-.

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-- Press the release buttons on the vacuum hose -1-, and remove the hose from the vacuum pump.

-- Place a cloth under the heater core for the heater to soak up any leaking coolant.

-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

-- Hold the coolant hoses downward and allow the coolant to drain.

-- Remove the connectors -1 and 2- from the bracket and disconnect them, and then free up the wires:

-- Remove the bolt -2- and the screw-type clamp.

-- Remove the nuts -1 and 3-. (Shown with the engine removed.)

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

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-- Remove and free up the hose -2- for the EVAP system to do so press the release buttons.

-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

• Use :80-200  in the following steps to remove the spiral clips.
  Fig 8: Free Electrical Wiring Up To Generator Using 80-200

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-- Disconnect the connector -1- from the Engine Control Module -J623-. Refer to ENGINE CONTROL MODULE -J623-, REMOVING AND INSTALLING .

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-- Remove the connectors -2 and 3- from the bracket and disconnect them and then free up the wires.

-- Remove the nut -4- and free up the ground wire.

-- Release the retainers in direction of -arrows-, and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver in direction of -arrow-, remove the cover -1- for the engine compartment E-box upward.

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

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-- Disconnect the connector -1- by sliding the retainer toward the rear and pressing the release downward.

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Vehicle with Manual Transmission:

-- Disconnect the left front connectors from the transmission:

1. For Transmission Neutral Position Sensor -G701-
2. For Back-Up Lamp Switch -F4-

-- Remove the gearshift and the selector lever cable from the transmission, remove the cable bracket and move it to the side with the cables. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING .

-- Remove the hose/line assembly from the breather on the clutch slave cylinder. Refer to appropriate service information. .

Vehicle with Dual-Clutch Transmission:

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-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING .

-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743- by turning the twist lock counter-clockwise in direction of -arrow-.

-- Disconnect the connector -arrow- for the differential lock.

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Continuation for All Vehicles:

-- Loosen the bolts -arrows- for the transmission mount approximately two turns.

-- Loosen the bolts -arrows- for the engine mount approximately two turns.

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-- Loosen the hose clamp -1-, remove the air duct hose from the charge air cooler.

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-- Disconnect the connector -1- for the radiator fan, to do this push the clip in the direction of -arrow A- and push the retainer downward.

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-- Press the left and right fan shroud locking tabs at the same time in direction of -arrow B- and remove the fan shroud downward from the radiator.

-- Loosen the hose clamp -2-.

-- Free up the coolant hose -3-.

-- Remove the bolts -arrows-.

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

-- Remove the right air duct pipe.

Vehicle with Parking Heater:

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-- Loosen the clamp -1-, remove the bolt -2- and remove the parking heater muffler.

Continuation for All Vehicles:

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

-- Remove the ribbed belt from the A/C compressor belt pulley and release the tension on the tensioner.

-- Remove the A/C compressor from the bracket with the refrigerant lines still attached and tie up to the right. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING .

AWD Vehicle:

-- Remove the right drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Remove the bolts -arrows- and remove the heat shield -1-.

-- Mark the position of flexible disc and the bevel box flange to each other for reinstallation.

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-- Using a lever to counterhold the triangular flange, remove the driveshaft from the bevel box -arrows-.

-- Secure the :T10323  with a bolt on the inner laying rear threaded hole for the subframe.

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-- A subframe bolt is suitable for this.

-- Place a cloth -A- on the :T10323  .

-- Remove the driveshaft from the bevel box.

Continuation for All Vehicles:

-- Remove or dismount the left and right drive axles from the flange shaft. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the drive axles to the rear.

• Do not damage the surface protection on the drive axle.

-- Loosen the clamping sleeve -arrow- and push it toward the rear.

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

-- Remove bolt -arrow- and push the bracket for the wiring harness aside.

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-- Install the :T10359/3  , as shown in the figure, on the :T10359A  .

-- Tighten the :T10359/2  onto the engine bracket with the securing element -A- from the :3282  .

-- Place the :T10359  in the :VAS6931  .

-- Attach the :T10359A  with the bolt -1- to 20 Nm on the cylinder block and secure with the support element -2- from the :3282  .

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-- Place the :VAS6931  on the :T10359A  and raise the engine/transmission subassembly slightly.

TIP:

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Use a step ladder to remove the subframe mount bolts.

-- Completely remove the engine mount bolts -arrows-.

-- Completely remove the transmission mount bolts -arrows- completely.

-- Carefully drain the engine/transmission assembly while doing so check is all vacuum lines or wires between the engine, transmission and body are separated.