Engine, Removing: Notes
Special Tools And Workshop Equipment Required
- Engine Sling:2024A
- Engine/Trans. Support:T10012
- Holding Fixture:VW313
- Holding Fixture:VW540
- Shop Crane:VAG1202A or Shop Crane:VAS6100
- Instrument/Gauge Tester:VAG1306 or Shop Crane - Drip Tray:VAS6208
- Torque Wrench 1331 5-50Nm:VAG1331
- Torque Wrench 1332 40-200Nm:VAG1332
- Engine and Gearbox Jack:VAS6931
- Hose Clip Pliers:VAS5024A
- Holding Fixture - Spacers:VW540/1B
- Lubricating Grease:G 000 100 (vehicles with manual transmission)
- Commercially available step ladder
- Hose Clamps - Up To 25 mm:3094
Perform the Following Work
-- Check the DTC memory for all control modules with the Vehicle Diagnostic Tester before removing.
To perform work sequence, the ground cable must be disconnected from battery. Check if a coded radio is installed. Get the anti-theft code beforehand, if necessary.
The engine is removed downward together with the transmission.
All cable ties, which are opened or cut open when removing the engine, must be replaced in the same position when installing the engine.
Seal off the disconnected fuel and ventilation lines to prevent dirt from getting into the system.
Leave the key in the ignition lock. This prevents the steering lock from engaging.
For all repair work, especially in the engine compartment due to the tight working conditions, observe the following:
- Route all lines and wires in their original locations.
- Ensure sufficient clearance to all moving or hot components.
-- Open clamps -1, 2, 3 and 9- and remove intake hose -10-.
-- Remove the brake booster vacuum hose -5- from the intake manifold.
-- Remove the air filter. Refer to OVERVIEW - AIR FILTER HOUSING .
-- Remove the battery and the battery tray. Refer to BATTERY .
-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .
-- Remove the E-box cover inside the engine compartment -arrows-.
-- Disconnect the line -2- and free it up.
-- Disconnect the connector -1- from the engine control module and free up the engine wiring harness. Refer to ENGINE CONTROL MODULE, REMOVING AND INSTALLING .
-- Disconnect the connector -4-, open the locking mechanism and lay the engine wiring harness -3- on the engine.
-- Disconnect the ground cable -1- and the starter connections -2 and 5-.
Vehicles with an Automatic Transmission
-- Disconnect the connector -6- from the multifunction switch.
-- Remove the selector lever cable from the transmission. Refer to SELECTOR MECHANISM (09G) .
-- Disconnect the connectors -1 and 2- from the transmission.
Vehicles with a Manual Transmission
-- Remove the gearshift mechanism from the transmission. Refer to SELECTOR MECHANISM (0AF) .
-- Remove the brace -1-.
-- Remove the clutch slave cylinder -arrows- and lay it to the side. To not open the line system.
Do not press the clutch pedal after removing the slave cylinder. Slave cylinder may be damaged by doing this.
-- Disconnect connector for back-up light switch from transmission.
Continuation for All Vehicles
-- Disconnect the connector for the Heated Oxygen Sensor -G39- on the bulkhead -item 14) COMPONENT LOCATION OVERVIEW - FUEL INJECTION SYSTEM - Connector for Heated Oxygen Sensor -G39- and free up the wiring harness.
-- Remove the coolant hoses from the heat exchanger -arrows-.
-- Open the spring clamps -arrows- and remove the coolant hoses from the radiator.
-- Disconnect the coolant hoses from the coolant reservoir.
-- Remove the air shroud with the radiator fans. Refer to Coolant Fan -V7- AND Coolant Fan 2 - V177-, REMOVING AND INSTALLING .
Fuel system is under pressure!
- Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin.
- Wrap a cloth around the wiring connections before loosening hose connections. Then release pressure by carefully pulling off the line.
-- Disconnect the fuel supply line -1-. Push the locking ring upward and into the housing.
-- Disconnect the breather line -2-. Press the locking ring.
-- Seal the lines so that the fuel system is not contaminated by dirt etc.
-- Remove the front exhaust pipe. Refer to OVERVIEW - EMISSIONS CONTROL .
-- Remove the right drive axle. Refer to DRIVE AXLE .
-- Remove the left drive axle from the transmission and tie it up.
-- Remove the bolt -1-.
-- Remove the bolts -2 and 3-.
-- Remove the pendulum support.
-- Remove the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .
-- Remove the clamps for the power steering pressure line on the transmission. Refer to POWER STEERING HYDRAULICS .
-- Remove the power steering pump from the auxiliary components bracket and move it forward. Refer to POWER STEERING HYDRAULICS .
- The power steering pressure line remains connected to the power steering pump.
-- Remove the bolt -3- and the ribbed belt tensioning damper -2-.
-- Remove the third bolt from the power steering fluid reservoir bracket (not illustrated).
-- Move the power steering fluid reservoir, with the hoses -1- and bracket still connected, to the side.
Vehicles with A/C System
-- Remove the A/C compressor with the refrigerant hoses still connected from the subassembly bracket.
Continuation for All Vehicles
-- Place the :T10012 in the :VAS6931 .
-- Attach the :T10012 to the cylinder block. Tighten the nut -2- and the bolt -1- to 20 Nm.
-- Insert the :VAS6931 into the :T10012 .
-- Lift the engine and transmission gently using the :VAS6931 .
Use a commercially available step ladder when removing the bolts on the engine/transmission mount.
-- Remove the engine mount from the engine support from the top -arrows-.
-- Remove the transmission mount from the transmission holder -arrows-.
Check that all hoses and lines between engine/transmission assembly and body have been disconnected.
A second technician is needed to lower the engine/transmission assembly.
The engine/transmission assembly must be guided with care to prevent damage while lowering.
-- Carefully lower the engine/transmission assembly. When doing this, rotate or push the engine/transmission assembly.