Removing engine

Locking pin -T10060 A-

Commercially available stepladder

Eye protection

Protective gloves

Procedure

Note

The engine is removed downwards together with the gearbox.

Reinstall all cable ties in the same locations when installing.

• Open cap -arrow- on coolant expansion tank.
• Remove left and right front wheel → Running gear, axles, steering; Rep. gr.44.
• Remove noise insulation → General body repairs, exterior; Rep. gr.66.
• Remove left and right front wheel housing liner → General body repairs, exterior; Rep. gr.66.
• Disconnect connector -2- from radiator outlet coolant temperature sender -G83--3-.
• Set drip tray for workshop hoist -VAS 6208- underneath.

• Lift retaining clip -1-, disconnect coolant hose from radiator (bottom left) and drain off coolant.

Note

Do not reuse coolant which has been drained off.

• Lift retaining clip -arrow-, disconnect coolant hose from water radiator (bottom right) for charge air cooling circuit and drain off coolant.
• If poly V-belt is to be reinstalled, mark direction of rotation on belt using chalk or felt tip pen before removing.

Vehicles with air conditioner compressor:

• To slacken poly V-belt, swivel tensioning device in anti-clockwise direction -arrow-, and detach poly V-belt from pulley for air conditioner compressor.
• Lock tensioner with locking pin -T10060 A-.
• Remove poly V-belt.

• Disconnect connector -1- on air conditioner compressor regulating valve -N280-.
• Remove bolts -arrows- for air conditioner compressor.
• Detach air conditioner compressor from bracket (refrigerant hoses remain connected) and tie up to right side. Do NOT stretch, kink or bend refrigerant lines and hoses while doing so.

Continuation for all vehicles:

• Release hose clip -1- and detach air hose.

• Unscrew bolt -2- on left and right.
• Unclip air duct at lock carrier and detach.

• Lift retaining clip -arrow- and disconnect coolant hose (top left) from radiator.

• Lift retaining clip -arrow- and disconnect coolant hose (top right) from water radiator for charge air cooling circuit.

• Unplug electrical connector -1- for radiator fan (push retainer to the rear -arrow A- and press down release catch).
• Press locking tabs on left and right sides of radiator cowl -arrow B- and at the same time lift radiator cowl off radiator.
• Disconnect battery → Electrical system; Rep. gr.27.
• Remove battery and battery tray → Electrical system; Rep. gr.27.

• Release catch -arrow- and disconnect vacuum hose -1-.
• Move clear vacuum hose at air pipe -2-.

Vehicles with no auxiliary heater

• Lift retaining clips -arrows- and disconnect coolant hoses from heat exchanger for heater.

Vehicles with auxiliary heater

• Release retaining clip and hose clip and pull off both coolant hoses -arrows-.

Vehicles with engine preheater heater element -Z97-

• Unclip locking mechanism -arrow-.

• Pull off wiring -1- on engine preheater heater element -Z97--2-.
• Unclip all cable ties from wiring harness -1- on engine and secure wiring harness on one side of the vehicle.
• Pull off lower coolant hose on engine preheating element -Z97- and remove coolant pipe.

• Unscrew nuts -arrows- and remove engine preheating element -Z97- with bracket.

Continuation for all vehicles

• Unscrew bolt -2- and remove screw-type clip.
• Remove bolt -1- and nuts -arrows- and tie up catalytic converter.

• Undo bolts -arrow- and remove bracket.

Place a cloth underneath to absorb escaping coolant.

Release hose clip -1- and pull off coolant hose.

• Observe the rules for cleanliness when working on the fuel supply system → Chapter.
• First press hose connector -1- downwards, and then press release tabs -arrows-.

• Keep release buttons pressed and pull off hose coupling.
• Press release tab on hose -2- connected to activated charcoal filter.
• Disconnect hose and move it clear.
• Detach air hose -2-.
• Remove air filter housing → Chapter.

Note

• Unplug upper electrical connector -1- at engine control unit -J623- → Chapter.
• Take electrical connectors -2- and -3- out of retainer and detach.
• Move electrical lines free.

• Disconnect electrical connector -2-.
• Push back cover for battery positive terminal -1- and unbolt battery positive cable from starter solenoid switch.
• Unbolt earth cable from body.

• Release catches -arrows- and detach cover -1- for electronics box in engine compartment.

• Release catch using a screwdriver -arrow- and detach cover -1- for electronics box in engine compartment upwards.

• Remove nut -arrow-, detach electrical wiring and move clear.

• Disconnect electrical connectors -1- and -2-.

Manual gearbox

• Remove selector mechanism from gearbox → Rep. gr.34.
• Remove clutch slave cylinder → Rep. gr.30.

Dual clutch gearbox

• Remove selector lever cable, pull connector of mechatronic off and remove all retainers from gearbox: → Rep. gr.34

Continuation for all vehicles

• Unscrew bolts -arrows- on engine mounting approx. 2 turns.

• Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.

• Disconnect electrical connector -1- on oil level and oil temperature sender -G266-.
• Detach wire from retainer -2-.

• Unscrew nuts for coupling rod -arrow- on left and right from anti-roll bar.

• Unscrew bolts -1, 2 and 3-, and remove pendulum support.

• Unscrew bolts -arrows- and remove heat shield for right drive shaft.

• Unscrew nuts -arrows- for swivel joint on left and right.

• If fitted, remove nut -arrow- from front left vehicle level sender -G78-.
• Detach swivel joint from transverse link on left and right.
• Unbolt drive shaft from gearbox on left and right, and tie it up → Running gear, axles, steering; Rep. gr.40.

Note

Take care not to damage the surface protection of the drive shaft.

• Swivel left suspension strut outwards and support it with extension -2024 A /1- as shown in illustration.
• Secure locking pin and swivel joint with locating pin -arrow- and nut -1-.

• Secure swivel joint -2- (right-side) to transverse link -1- with nut -arrow-, as shown in illustration.
• Apply clamping piece T10497/2 at housing rib on cylinder block, as shown in illustration.

Vehicles with four-wheel drive

• Unbolt flexible coupling of propshaft from bevel box → Final drive, differential; Rep. gr.39.

Continuation for all vehicles

• Position engine support T10497 with pin T10497/1 on cylinder block.
• Screw in bolt -1- through hole “B” in engine support T10497 and tighten it to 20 N·m.

• Fit adapter -T10497/3- to engine support -T10497- and tighten bolt -1- to 20 N·m.
• Insert engine and gearbox jack -V.A.G 1383 A- in engine support T10497 and raise engine/gearbox assembly slightly.

Note

To unscrew bolts for assembly mounting use commercially available stepladder.

• Remove bolts -arrows- for engine mounting.

• Remove bolts -arrows- securing gearbox mounting.

• First lower engine/gearbox assembly slightly.
• Then push gearbox end of engine/gearbox assembly forwards and only then lower further.