Engine, removing and installing

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Miranda Hannah Watson
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1 Стр 1 из Engine, removing and installing Special tools, testers and auxiliary items required Torque wrench VAG 1331 Torque wrench VAG 1332 Engine/transmission jack VAG 1383 A Spring type clip pliers VAS 5024A Step ladder VAS 5085

2 Стр 2 из 16 Engine/Trans Support T10012 Cable ties Removing engine 10-1, Engine, removing Securing engine to engine stand to engine stand 10-1, Attaching engine Installing engine Subframe mount 10-1, Engine, installing 10-1, Subframe mount Engine, removing Securing engine to engine stand to engine stand 10-1, Attaching engine Note: In the continuing work procedure, the battery Ground (GND) strap must be disconnected Determine whether a coded radio is installed If necessary, determine anti-theft coding first Engine is removed downward with transmission All cable ties opened or cut during engine removal must be reinstalled at the same locations Caution! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (eg for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components - Disconnect battery Ground (GND) strap with ignition switched off

3 - - Pull and jerk engine cover upward at front and remove engine cover - Remove battery and

3 Стр 3 из 16 Repair Manual, Electrical Equipment, Repair Group 27, Battery; disconnecting and connecting battery - Disconnect intake hose Disconnect connector Remove bolts Pull and jerk engine cover upward at front and remove engine cover - Remove battery and battery holder - Remove plenum chamber bulkhead Repair Manual, Body Exterior, Repair Group 50, Front

Стр 4 из 16 body, plenum chamber bulkhead - Disconnect engine wiring harness connector from Engine Control Module (ECM) - Release pass-through for engine wiring

wiring harness/body and set down engine wiring harness on engine Warning! Fuel supply line is under pressure!

4 Стр 4 из 16 body, plenum chamber bulkhead - Disconnect engine wiring harness connector from Engine Control Module (ECM) - Release pass-through for engine wiring harness - arrow - and remove upward - Open locking mechanisms of cable guide on longitudinal member - arrows - - Disconnect all harness connectors of engine wiring harness/body and set down engine wiring harness on engine Warning! Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin Before loosening hose connections, place rags around the connection point Then release pressure by carefully pulling on hose

Стр 5 из 16 - Disconnect lines - 1, 2 and 3 -

- Remove lower wheel housing liner on left

5 Стр 5 из 16 - Disconnect lines - 1, 2 and 3 - To do so, press release buttons - Remove insulation pan Repair Manual, Body Exterior, Repair Group 50, Front body; noise insulation - Remove lower wheel housing liner on left and right - Disconnect charge air hoses - arrows -

Стр 6 из 16 - Remove heat shield for right drive axle - arrows- - Remove left and right drive axle Repair Manual, Suspension, Wheels, Steering, Repair Group 40, Drive axle, removing and installing -

6 Стр 6 из 16 - Remove heat shield for right drive axle - arrows- - Remove left and right drive axle Repair Manual, Suspension, Wheels, Steering, Repair Group 40, Drive axle, removing and installing - Remove front pipe with catalytic converter 26-1, Catalytic converter with front exhaust pipe, removing and installing - Bring lock carrier into service position Repair Manual, Body Exterior, Repair Group 50, Body front, lock carrier service position - Drain engine coolant 19-1, Coolant, draining and refilling - Empty A/C system Repair Manual, Heating Air Conditioning, Repair Group 87, A/C System with R134a refrigerant

Стр 7 из 16 - Remove A/C line - arrow - from compressor -

3 - and remove pendulum support - Remove all remaining electrical

Disconnect all connection, coolant, vacuum and intake hoses from

7 Стр 7 из 16 - Remove A/C line - arrow - from compressor - Disconnect A/C line from condenser - arrow- - Remove bolts - 1 to 3 - and remove pendulum support - Remove all remaining electrical wires necessary from engine/transmission and set aside - Disconnect all connection, coolant, vacuum and intake hoses from engine Vehicles with manual transmission: - Remove shift mechanism from transmission

Стр 8 из 16 Repair Manual, Manual transmission, Repair Group 34, Shift mechanism, servicing - Remove brace - 1 - - Remove slave cylinder - arrows - and set aside, do not open line system Caution!

8 Стр 8 из 16 Repair Manual, Manual transmission, Repair Group 34, Shift mechanism, servicing - Remove brace Remove slave cylinder - arrows - and set aside, do not open line system Caution! Do not press clutch pedal after clutch slave cylinder has been removed By doing this, slave cylinder may be damaged Vehicles with automatic transmission - Remove selector lever cable from transmission Repair Manual, Automatic Transmission, Repair Group 37, Shift mechanism, servicing Continued for all vehicles:

T10012 on engine as shown and tighten bolt - 1 - and nut - 2 - to approx 20 Nm

9 Стр 9 из 16 - Remove Coolant Pump V50 - arrows - - Insert Engine/Trans Support T10012 in engine/transmission jack VAG 1383 A - Attach Engine/Trans Support T10012 on engine as shown and tighten bolt and nut to approx 20 Nm - Gently lift engine and transmission using engine/transmission jack VAG 1383 A

Use step ladder VAS 5085 to remove mounting bolts Engine and transmission must be lowered carefully

10 Стр 10 из 16 - Remove subframe mount from engine bracket - arrows - on engine side, from above - Remove subframe mount from transmission bracket - arrows - on transmission side from above Note: Use step ladder VAS 5085 to remove mounting bolts Engine and transmission must be lowered carefully to avoid damaging body - Lower engine and transmission carefully downward Attaching engine to engine stand

11 Стр 11 из 16 Special tools, testers and auxiliary items required Engine sling 2024 A Workshop crane VAS 6100 Engine and Transmission Holder VAS 6095 Secure engine using Engine and Transmission Holder VAS 6095 when performing repair work - Unflange transmission

Стр 12 из 16 - Attach engine sling 2024 A as follows and lift out using workshop crane VAS 6100 from engine/transmission jack VAG 1383 A Belt pulley side: 2nd hole of rail in position 1 Flywheel

12 Стр 12 из 16 - Attach engine sling 2024 A as follows and lift out using workshop crane VAS 6100 from engine/transmission jack VAG 1383 A Belt pulley side: 2nd hole of rail in position 1 Flywheel side: 1st hole of rail in position 7 Caution! Use securing pins at hook and drifts in order to prevent damage on engine and on vehicle The peg positions on the carrying strap marked with 1 through 4 face belt pulley Holes in rails are counted from hook - Secure engine on engine and transmission holder VAS 6095 Engine, installing Subframe mount 10-1, Subframe mount Installation is in reverse order of removal, note the following: Caution! Observe the following for all installations, especially in engine compartment due to lack of room: Route lines of all types (eg for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed To prevent damage to the lines, make sure there

Стр 13 из 16 is sufficient clearance to all moving or hot components - Insert new centering sleeves for centering engine/transmission in cylinder block - Engage intermediate plate at sealing flange

13 Стр 13 из 16 is sufficient clearance to all moving or hot components - Insert new centering sleeves for centering engine/transmission in cylinder block - Engage intermediate plate at sealing flange and slide onto alignment bushings - arrows - Vehicles with manual transmission: - Grease input shaft splines lightly with grease grease G Check and install clutch and clutch mechanism Repair Manual, Manual transmission, Repair Group 30, Clutch mechanism, servicing Continued for all vehicles: - When installing engine/transmission assembly, check for clearance to subframe as well as to radiator - Align engine mount free of tension by using shaking motions, also loosen engine mount at chassis if necessary - Install pendulum support Note: Tightening torque of subframe mount 10-1, Subframe mount Harness connectors and routing

14 Стр 14 из 16 - Install front exhaust pipe - Install right and left drive axle Repair Manual, Suspension, Wheels, Steering, Repair Group 40, Drive axle, removing and installing Vehicles with manual transmission: - Install shift mechanism and adjust, if necessary Repair Manual, Manual Transmission, Repair Group 34, Shift mechanism, servicing - Install slave cylinder for hydraulic clutch Repair Manual, Manual Transmission, Repair Group 30, Clutch mechanism, servicing; assembly overview - hydraulics Vehicles with automatic transmission - Install selector lever cable and adjust, if necessary Repair Manual, Automatic Transmission, Repair Group 37, Shift mechanism, servicing Continued for all vehicles: - Install insulation pan Repair Manual, Body Exterior, Repair Group 50, Front body; assembly overview - Install plenum chamber bulkhead

Стр 15 из 16 Repair Manual, Body Exterior, Repair Group 50, Front body, plenum chamber bulkhead - Fill with coolant 19-1, Coolant, draining and refilling - Connect battery Repair Manual, Electrical

15 Стр 15 из 16 Repair Manual, Body Exterior, Repair Group 50, Front body, plenum chamber bulkhead - Fill with coolant 19-1, Coolant, draining and refilling - Connect battery Repair Manual, Electrical Equipment, Repair Group 27, Battery disconnecting and connecting - Adapt Engine Control Module (ECM) Vehicle Diagnosis, Testing and Information System VAS 5051 "Guided Function" - Perform a road test and check DTC memory afterwards Tightening torques: Threaded connection Tightening torque Nuts, bolts M 6 10 Nm M 7 15 Nm M 8 25 Nm M10 40 Nm M12 60 Nm Subframe mount Engine subframe mount A ) = 20 Nm plus an additional 90 B ) = 40 Nm plus an additional 90 (1/4 turn) (1/4 turn)

16 Стр 16 из 16 C ) = 60 Nm plus an additional 90 (1/4 turn) ) Replace Transmission subframe mount A ) = 40 Nm plus an additional 90 B ) = 60 Nm plus an additional 90 (1/4 turn) (1/4 turn) ) Replace Pendulum supports A ) = 40 Nm plus an additional 90 B ) = 100 Nm plus an additional 90 (1/4 turn) (1/4 turn) ) Replace

Transmission, removing and

Page 1 of 20 34-18 Transmission, removing and installing Removing Special tools and equipment 3282 transmission support 3282/10 adjustment plate 3337 ring spanner 7-piece set VAG1383A engine/transmission