1.4 TSI engine (EA211) · Removing and installing engine · Removing and installing engine

Removing engine

Special tools and workshop equipment required

  • Release lever - 80 - 200-
  • Engine and gearbox jack - V.A.G 1383 A-
  • Engine support - T10497-
  • Drip tray for workshop hoist - VAS 6208-
  • Spring-type clip pliers - VAS 6362-
  • Commercially available stepladder
  • Safety glasses
  • Safety gloves

Removing

  • Carefully open filler cap -1- on coolant expansion tank -2- in -direction of arrow-.
  • Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27; Battery; Removing and installing battery tray.

Vehicles with manual gearbox

  • Pull vacuum line -1- off brake servo -2-.
  • If fitted, release and disconnect connector on vacuum sender on vacuum line.

Continued for all vehicles

  • Carefully loosen wiring harness at its fastening points -arrows-.
  • Release connector -arrow-, pull off and unclip from bracket.
  • Release connector from engine control unit and pull off ⇒ 6 Engine control unit.
  • Place wiring harness on engine.
  • Remove front wheels ⇒ Running gear, axles, steering; Rep. gr. 44; Wheels, tyres; Specified torque for wheel bolts.
  • Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 66; Noise insulation.
  • Remove front left and right wheel housing liners ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing liner.
  • If fitted, release and pull off connector -1- on oil level and oil temperature sender - G266-.
  • Move clear electrical wiring harness, and lay it to one side.
  • Remove heat shield for right drive shaft ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and installing drive shaft heat shield.
  • Remove left and right drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
  • Remove radiator cowl ⇒ 4.5 Removing and installing radiator cowl with radiator fan.

Vehicles with air conditioner compressor:

  • Remove poly V-belt ⇒ 1.3 Removing and installing poly-V belt.
  • Separate connector -1- on air conditioning compressor regulating valve - N280-.
  • Remove air conditioner compressor with refrigerant lines connected from engine ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Removing air conditioner compressor from and installing to bracket.
  • 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.

Continued for all vehicles

  • Loosen clamp -arrow-, and push it to rear.
  • Detach exhaust hangers -3- in -direction of arrow- from subframe -2-.
  • Lower exhaust system -1- until it rests on subframe -2-.
  • Unscrew bolt -2-.
  • Remove screw-type clip -1-.
  • Unscrew nuts -arrows- and tie up catalytic converter -3-.
  • Unscrew bolts -arrows- and remove bracket -1-.
  • Open spring-type clip -arrow- and pull off coolant hose downwards.
  • Open spring-type clips -arrows-.
  • Pull coolant hose -1- off radiator -2-.
  • Open spring-type clips -arrows-.
  • Pull coolant hoses -1- off water radiator for charge air cooling circuit -2-.
  • Release retaining clips -arrows-.
  • Pull coolant hoses -1- off heat exchanger for heater unit.
  • Release and pull off connector -2- on starter -1-.
  • Pull off protective cap -3-.
  • Unscrew nut -arrow- and remove line from starter -1-.
  • Release and pull off connectors -2-.
  • Unclip connectors -2- from bracket -1-.
  • Unclip wires -3- and -4- from bracket -1-.
  • Unscrew nuts -arrow-.
  • Remove bracket -1- from gearbox.
  • Release and pull off connector -3- on alternator -2-.
  • Unscrew nut -4-.
  • Remove wire -1- from alternator -2-.
  • Lay wiring harness -1- on coolant hose to one side.
  • Lay lower wiring harness on intake manifold to one side.
  • Use removal lever - 80 - 200- to do this.

Vehicles with manual gearbox

  • Release and pull off connectors on gearbox.
  • Remove selector mechanism from gearbox ⇒ Rep. gr. 34; Selector mechanism; Removing and installing selector mechanism.
  • Remove clutch slave cylinder ⇒ Rep. gr. 30; Clutch mechanism; Removing and installing clutch slave cylinder.

Vehicles with dual clutch gearbox

  • Release catch -arrow- and disconnect vacuum hose -1-.
  • Move clear vacuum hose at air intake pipe -2-.
  • Remove selector lever cable -1- ⇒ Rep. gr. 34; Removing and installing gearbox.
  • Unscrew bolts -2- on gearbox.
  • Lay selector lever cable with retainer to one side.
  • Release and pull off connector -1- of mechatronic unit in -direction of arrow-.
  • Unscrew bolts -2- and -3-.
  • Remove retainer with wiring harness and lay them to one side.
  • Pull vacuum line -2- in direction of -arrow- off vacuum pump for brakes - V192- -1-.
  • Lay vacuum line -1- to one side.

Continued for all vehicles

  • Release connectors -2- and pull off.
  • Unscrew securing bolts -3-.
  • Place coolant expansion tank -1- on engine.
  • Disconnect fuel supply line -1- and line to activated charcoal filter solenoid valve 1 - N80- -2-. Disconnect plug-in connectors ⇒ Rep. gr. 20; Plug-in connectors; Disconnecting plugin connectors.
  • Unscrew earth wire -1-.
  • Unscrew bolts -arrows- on engine mounting approx. 2 turns.
  • 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 Nm.
  • Fit adapter - T10497/3- to engine support - T10497- and tighten bolt -1- to 20 Nm.
  • Insert engine and gearbox jack - V.A.G 1383 A- in engine support T10497, and raise engine/gearbox assembly slightly.
  • Remove bolts -arrows- for engine mounting.
  • Unscrew securing bolts -arrows- from gearbox mounting.
  • Check that all vacuum lines and electrical wiring between engine, gearbox, subframe and body have been detached.
  • When lowering, carefully guide engine/gearbox assembly with assembly carrier out of engine compartment.
  • First lower engine/gearbox assembly slightly.
  • Then push gearbox end of engine/gearbox assembly forwards and only then lower further.