Notes on removing

NOTE:

The engine is removed downward together with the transmission.
All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

With ignition switched off disconnect battery Ground (GND) strap.
Remove engine cover.
Remove spark plug connectors and unclip spark plug wires.
Remove battery and battery holder.

Remove the air filter and intake tube, refer to Air filter, assembly overview .

CAUTION: Fuel supply lines are under pressure! Wear eye protection and protective gloves to avoid injuries and skin contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Fig 1: Identifying Supply Line And Return Line

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Pull off supply line - 1 - (with white marking) and return line - 2 - (with blue marking) and catch any released fuel with a shop rag.

NOTE:

Press buttons on hose couplings to do this.

Seal lines so that the fuel system is not contaminated by dirt etc.
Remove sound insulation pan, along with left and right sides: Refer to BODY EXTERIOR
Remove ribbed belt, refer to Ribbed belt, removing and installing under Ribbed belt, removing and installing .
Remove power steering pump on compact bracket and place to side; hoses remain connected: Refer to 48 STEERING

Remove securing clamps for power steering pressure line.

Vehicles with air conditioning

Observe additional information and removal work, refer to Additional information and assembly work on vehicles with air conditioning under Additional information and assembly work on vehicles with air conditioning .

Continued for all vehicles

Disconnect selector mechanism from transmission: Refer to 34 - MANUAL TRANSMISSION - CONTROLS, HOUSING
Separate hydraulic line to slave cylinder for hydraulic clutch: Refer to 30 - CLUTCH
Remove front bumper cover: Refer to 63 BUMPER
Bring lock carrier into service position: Refer to 50 BODY, FRONT

Remove intake manifold, refer to Cylinder head cover, removing and installing .
Pull vacuum and vent hoses off from the engine.
Separate the electrical connectors on the following components:

NOTE:

Before disconnecting harness connectors, mark allocation to component.

Engine Coolant Temperature (ECT) Sensor G62 with Engine Coolant Temperature (ECT) Gauge Sensor G2
After-run coolant pump V51
Valve 1 for camshaft adjustment N205
Camshaft Adjustment Valve 1 (exhaust) N318
Camshaft Position (CMP) sensor G40
Camshaft position (CMP) sensor 2 G163
Cylinder 1 Fuel Injector N30 to Cylinder 6 Fuel Injector N84
Engine speed (RPM) sensor G28
Knock sensor 1 G61
Knock sensor 2 G66
Oil level thermal sensor G266

Installed location: Refer to Component locations, overview

Pull off/disconnect all electrical connections as necessary from engine and lay aside.
Pull off/disconnect and lay aside all electrical harnesses from transmission, alternator, and starter.
Drain the coolant, refer to Cooling system, draining and filling under Cooling system, draining and filling .
Remove quick acting couplings of coolant hoses from radiator.

Pull off coolant hoses from engine using spring type clip pliers VAS 5024A.
Remove drive shafts: Refer to 40 FRONT SUSPENSION

Fig 2: Identifying Pendulum Supports

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Remove pendulum supports - arrows -.
Remove double catalytic converter, refer to Exhaust system components, removing and installing .
Remove front driveshaft tube: Refer to 39F - FINAL DRIVE, FRONT DIFFERENTIAL or 39R - FINAL DRIVE, REAR DIFFERENTIAL
Remove front exhaust pipe, refer to Exhaust system components, removing and installing .

Remove generator and compact holder: Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Remove holder for secondary air injection (AIR) pump motor V101 from oil pan.
Set engine/transmission support T10102 onto engine/transmission jack V.A.G 1383 A.

Fig 3: Identifying Engine/Transmission Support T10102 And Engine/Transmission Jack V.A.G 1383 A

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Set engine holder T10102 onto cylinder block and fasten with bolts - 1 -.
Lift engine and transmission slightly using engine/transmission jack V.A.G 1383 A.

Fig 4: Identifying Engine Side Of Assembly Mounting At Engine Bracket At Top

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Unbolt engine side of assembly mounting from engine bracket at top - arrows -.

NOTE:

Use step ladder VAS 5085 to remove bolts.

Fig 5: Identifying Transmission Side Of Assembly Mounting At Top Of Transmission Carrier

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Unbolt transmission side of assembly mounting from top of transmission carrier - arrows -.
Carefully lower engine with transmission.

NOTE:

Carefully guided engine with transmission, when lowering, to prevent damage to bodywork.