Removal
NOTE:
- Numbers in ( ) refer to points in the applicable image.
- Engine is removed upward without the transmission.
- All tie wraps that are loosened or cut during engine removal must be put back on in the same place when the engine is installed.
CAUTION:
- Determine correct radio anti-theft coding before disconnecting the battery.
- Disconnect battery Ground (GND) strap with ignition switched off.
NOTE:
- On vehicles without fresh air filter or air conditioner, battery is located in plenum chamber on right.
- On vehicles with fresh air filter or air conditioner, it is located under rear seat cushion.
Removal
- Remove noise insulation panel (arrows).
- Disengage additional front retaining clips in center of noise insulation panel.
- Remove front bumper.
- Remove lock carrier (upper radiator support) with attached parts.
- Position oil catch pan VW 1306 under engine compartment.
- Open plug on coolant expansion tank.
- Turn quick fasteners (arrows) on connector cover on rear engine compartment bulkhead 900 to left and remove cover.
- Plug water hoses to heater with special hose clamps 3094.
- Drain coolant at cooler (arrow), push auxiliary hose onto drain petcock if necessary.
- Unscrew right air duct at radiator (arrows) and remove.
- Remove radiator (Vehicles Without Air Conditioner)
^ Remove oil cooler for hydraulic oil at radiator (1) and hang up on body (hoses remain connected).
^ Disconnect coolant hoses at radiator.
^ Remove radiator (2).
- Reposition radiator (Vehicles With Air Conditioner)
^ Radiator remains installed.
^ Remove bracket for trim plate (2) on right side of vehicle.
^ Remove right and left radiator attachment (3).
^ Remove left air guide from radiator (1).
^ Install support device 3251 to right bumper bracket and swing radiator forward.
- Disconnect air hose between Mass Air Flow (MAF) sensor and turbocharger (4) at MAF sensor.
- Remove connector at MAF sensor (3).
- Remove retaining bolt (1).
- Release four spring clips (2).
- Remove upper section of air cleaner housing and remove air cleaner element.
- Disconnect intake hose and remove lower section of air cleaner housing.
- Disconnect upper hose to radiator (2) at radiator and coolant manifold and put aside. T-shaped hose to expansion tank remains connected.
- Remove cover (1) above ribbed belt.
- Remove connector at throttle position sensor (3).
- Remove air hose (4).
- Remove viscous clutch. Use spanner wrench 3212 to brace with wrench 3312 to remove.
- Lay viscous fan in fan frame.
- If necessary, unclip lower wiring harness from fan frame.
- Loosen bolts on belt pulley of vane pump for power steering.
- Relieve tension on poly-ribbed belt by turning tensioner in direction shown (arrow) with open-end wrench and insert pin 3204 into hole.
- Remove ribbed belt.
- Remove belt pulley of vane pump for power steering.
- Remove power steering hose from bracket on left engine mount.
- Remove vane pump for power steering and set aside in engine compartment.
NOTE: Hoses remain connected.
- Disconnect harness connectors (arrows):
^ Thermoswitch (2-pin)
^ Thermoswitch (4-pin)
^ Engine oil pressure sensor (white insulation)
^ Engine oil pressure sensor (for gauge)
- Disconnect wires from alternator and loosen cable clip.
- Remove retaining clip for refrigerant and coolant line ref. arrow, (vehicles with A/C)
- Remove retaining tab for upper coolant line ref. arrow, (Vehicles without A/C).
- Detach throttle cable (3).
- Pull off connector at idle air control valve (2).
- Pull off connector and supply hose at Evaporative Emission (EVAP) canister purge regulator valve (1).
- Mark connectors on rear engine compartment bulkhead and separate:
(1) Black 3-pin connector for ignition coil with power output stage 2 (two pins used in connector)
(2) Brown 3-pin connector for power output stage
(3) Black single-pin connector (round) for Heated Oxygen Sensor (HO2S)
(4) Black 2-pin connector for HO2S
(5) White 3-pin connector for ignition coils in cylinder head (lower connector section, three pins connected)
(6) White 3-pin connector for ignition coils in cylinder head (lower connector section, two pins connected)
(7) Black 3-pin connector for Crankshaft Position (CKP) sensor
(8) Grey connector for Engine Speed (RPM) sensor
(9) Brown connector for knock sensor 1
(10) Blue connector for knock sensor 2
- Unscrew Intake Air Temperature (IAT) sensor (1) on throttle housing.
- Disconnect harness connectors (2) for electric coolant pump and (3) for Camshaft Position (CMP) sensor.
- Pull through wiring harness toward rear and expose.
- Unscrew fuel injector cover.
- Disconnect harness connectors from fuel injectors and expose wiring harness.
- Disconnect ground wires.
- On upper intake manifold, wiring color brown/red.
- On rear intake manifold, wiring color brown/white.
- Disconnect harness connector from thermoswitch at back side of cylinder head.
- Disconnect coolant hoses to heater on engine.
- Separate fuel and vacuum lines (arrows).
- To avoid damage, remove Engine Speed (RPM) sensor above flywheel (arrow).
- Unscrew bolts on engine/transmission flange accessible from above (arrows).
NOTE: One engine/transmission bolt remains screwed in hand-tight.
- Disconnect harness connector from wastegate bypass regulator valve (arrow).
- Disconnect pressure line between turbocharger and intercooler (arrows).
- Remove starter (arrows).
- Vehicles with automatic transmission, remove three bolts of torque converter in opening of removed starter (turn crankshaft 1/3-turn each time).
- Disconnect ground wire (1) from right longitudinal member.
- Mark oil lines (2) and disconnect from oil filter flange, allowing oil to drip into catch pan.
- Vehicles With Air Conditioner, remove bracket (arrow) for refrigerant hose at oil sump.
CAUTION:
- Disconnect brackets and mounting points only.
- DO NOT open the air conditioning refrigerant circuit. Refrigerant lines kink easily.
^ Unscrew and remove coolant line (3).
^ Unscrew A/C compressor (arrows) and hang up on side.
CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.
^ Detach wire (2) from engine oil temperature sensor.
^ Remove lower coolant hose (1) to radiator.
- Remove front exhaust manifold.
- Unscrew bolts at bottom left and right (arrows).
- Unscrew three bolts (1) on corrugated pipe.
- Unscrew four nuts (2) on turbocharger/exhaust pipe flange.
NOTE: To remove lower rear nuts (2) on turbocharger/exhaust pipe flange, 15 mm flat box wrench (bottom) must be bent to fit (arrow). Size of remaining nuts on turbocharger/exhaust pipe flange is 17 mm.
- Remove exhaust pipe downward.
- Remove cover for right drive shaft (arrows).
- Unscrew nuts of left and right engine mounts (arrow).
- Unscrew bolts on engine/transmission flange accessible from below.
- Remove cross-member with torque arm. To do this, remove pressure reservoir bracket from left longitudinal member and torque arm from engine. Unscrew four bolts (arrows) and remove cross-member.
- Position transmission support 1O-222 A on fender attachment lip.
- Hook transmission mount 3147 into upper right bolt hole of transmission bell housing (shown with engine removed).
NOTE: Height of transmission can be adjusted with wing nut of support hook.
- Hook engine support 2024 A to engine and to workshop crane 1202.
NOTE: In order to balance the engine's center of gravity, bars for lifting hooks must be connected as shown in diagram.
WARNING: Hooks and pins of engine support must be secured with safety clips (arrows in diagram).
- Ensure sufficient space between engine support and vacuum hose (arrow). Remove hose if necessary.
- Lift engine with workshop crane using pins of engine mountings.
- Retighten wing nut on transmission support 10-222A accordingly.
- Upper engine/transmission flange: Unscrew last bolt.
- Pull engine off transmission and lift upward out of engine compartment.
NOTE: Guide engine carefully when lifting out in order to avoid damaging clutch, body and radiator:
- After removing engine, secure torque converter in transmission from falling out, if vehicle is equipped with automatic transmission.
- Secure engine to repair stand with engine and transmission bracket VW 540 in order to carry out repairs.
NOTE: Do not measure cylinder bores with engine mounted on repair stand.