Work sequence

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, 2003 Volkswagen Jetta, and 2003 Volkswagen GTI. However, it is still accessible from the selected car via links, so may be relevant.

Remove engine cover.
First check whether a coded radio is installed. If so, obtain anti-theft coding.
With ignition switched off disconnect battery Ground strap.

Fig 1: Identifying Ignition Coils

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Disconnect connectors from ignition coils 1...6.

NOTE:

Mark connector and component before disconnecting.

Remove ignition coils with final out stage for cylinders 1...6 using puller T10095.
Remove battery and battery retainer.
Remove air cleaner with intake hose: → 24 MULTIPORT FUEL INJECTION (MFI)

Fig 2: Identifying Vacuum Hose To Throttle Valve Control Module, Fuel Return Hose & Fuel Supply Hose

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Disconnect following hose connections and collect fluids that may leak out with a cloth:

1 - vacuum hose to Throttle valve control module - J338 - ,

2 - fuel return hose (with blue markings),

3 - fuel supply hose (with white markings).

NOTE:

Press buttons on hose couplings to disconnect.

CAUTION: Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Seal lines to avoid contamination of fuel system.
Observe rules for cleanliness → Rules for cleanliness .
Remove center, left and right insulation trays: → 50 BODY, FRONT
Pull connectors off thermal switch and coolant fan.

Remove front bumper: → 63 BUMPER
Bring lock carrier into service position: → 50 BODY, FRONT
Remove intake manifold → Cylinder head cover, removing and installing , Removing and installing cylinder head cover.

NOTE:

Seal the intake ports in the intake manifold or in the cylinder head with a clean cloth.

Remove ribbed belt → 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: → 48 STEERING
Remove securing clamps for power steering pressure line.

Vehicles with air conditioning

Observe additional information and removal work → Additional information and assembly work on models with air conditioning under Additional information and assembly work on models with air conditioning .

Models with a manual transmission

Disconnect selector mechanism from transmission: → 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 & 6 SPD. MANUAL TRANSMISSION 02M or 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION 02J
Separate hydraulic line to slave cylinder for hydraulic clutch: → 30 CLUTCH for 5 & 6 SPD. MANUAL TRANSMISSION 02M, 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 02J or 30 - CLUTCH 6 SPD. MANUAL TRANSMISSION 02Y ALL WHEEL DRIVE

Models with an automatic transmission

Remove gate selector lever cable from transmission: → 37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 4 SPD. AUTOMATIC TRANSMISSION 01M or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 09A

Continuation for all vehicles

Disconnect vacuum and breather hoses from engine.
Separate connectors on following components:

NOTE:

Mark connector and component before disconnecting.

Engine Coolant Temperature (ECT) sensor G62 with Engine Coolant Temperature (ECT) 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 ,
Injectors -N30- to -N33-, -N83- and -N84- ,

Engine speed (RPM) sensor G28 ,
Knock Sensor (KS) 1 G61 ,
Knock Sensor (KS) 2 G66 ,

Installation locations: → 24 MULTIPORT FUEL INJECTION (MFI)

Disconnect all electric wires from transmission, alternator and starter and them move clear.
Disconnect all other electrical connections from engine as necessary and place to one side.
Drain coolant → Cooling system, draining and filling .
Disconnect coolant hoses quick release couplings from radiator.

Pull all coolant hoses off to engine using Assembly tool for spring-type clips VAS 5024.
Removing drive shafts: → 40 FRONT SUSPENSION
Remove pendulum support: → 40 FRONT SUSPENSION
Remove front exhaust pipe with catalytic converter → Exhaust system components, servicing , Removing and installing parts of the exhaust system.

Remove alternator and compact bracket: → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Unscrew bracket for Secondary Air Injection (AIR) pump motor V101 from oil pan and cylinder block, -.
Install engine bracket 3395 onto Engine and gearbox jack VAG 1383 A.

Fig 3: Engine Bracket 3395 With V.A.G 1383 A Install To Cylinder Block

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Install engine bracket 3395 to cylinder block and tighten securing nuts - 1 - to 40 Nm.
Lift engine and transmission slightly using Engine and gearbox jack VAG 1383 A.

Fig 4: Locating Engine Carrier Bolts (Engine Side)

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

NOTE:

Use ladder VAS 5085 to remove securing bolts.

Fig 5: Locating Engine Carrier Bolts (Transmission Side)

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Unbolt transmission side of assembly mounting from top of transmission carrier - arrows -.

NOTE:

Use Ladder VAS 5085 to remove securing bolts.

Carefully lower engine with transmission.

NOTE:

Engine with transmission must be guided carefully, when lowering, to prevent damage to bodywork.