Removal

Notes:
- All tie wraps that are loosened or removed in order to remove the engine must be replaced or reinstalled in the same place when the engine is installed.
- Only remove and install the spark plugs using 3122B spark plug removal tool.

- Switch ignition off and disconnect battery Ground strap.

CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.





- Remove engine cover (arrows).





- Remove noise insulation panel (arrows).
- Remove front bumper.





- Remove bolts (arrows) for power steering hydraulic fluid cooling line and make sure that it is free. Do not open hydraulic fluid circuit.
- Open cap on engine coolant expansion tank.

WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.

- Place clean VW1306 receptacle or drain pan under engine.





- Unscrew drain plug (arrow) on left-side of radiator. Install drain hose to connection if necessary.





- Open engine coolant drain screw on engine (arrow) using 3247 hex ball socket.

CAUTION: Dispose of used coolant properly.

Vehicles with air conditioning

CAUTION: The A/C refrigerant circuit must only be opened by specialty trained technicians using the proper tools and equipment.
- DO NOT open the air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending. Refrigerant lines kink easily.





- Remove left and right-side air grills for radiator -4-.
- Remove condenser mounting bolts -1- and -2-.
- Disconnect harness connector -3- for A/C pressure switch -F 129-.
- Pull condenser up out of its bracket, rotate it to side and use wire to secure it on or near right-front wheel.

All models





- Disconnect 5 harness connectors (arrows) located below trim cover in front of ABS hydraulic control unit.
- Remove radiator hoses from radiator (top-left and bottom right).
- Remove bolts for air duct for air cleaner housing at front apron and lift air duct out.
- Remove lock carrier with attachments.
- Remove engine coolant expansion tank.





- Remove intake air hose between Mass Air Flow (MAF) sensor and intake air elbow.
- Disconnect Evaporative Emission (EVAP) canister purge regulator valve and remove valve from retainer.
- Disconnect harness connector for mass air flow sensor.
- Disconnect fuel supply and return lines.

WARNING:
- Fire hazard! Do not smoke or have anything in the area that could ignite fuel or fumes.
- Fuel system is under pressure! Before opening the system place a rag around the connection. Then release pressure by carefully loosening the connection.





- Turn air duct for Secondary Air Injection (AIR) pump 1/4-turn (90°) toward right and remove.
- Remove air cleaner housing.





- Remove wiper arms (arrows).
- Pull off retaining clips -1- and -3- on water deflector.
- Remove water deflector.
- Remove cover -2- from electronics box (E-box).
- Disconnect retainer for Engine Control Module (ECM).





- Remove ECM, release harness connectors -2- and -3- and disconnect from ECM.
- Disconnect harness connectors -1-.
- Disengage wiring harness (arrow) and move it clear to one side.





- Disconnect ground connection -2- and retainer for harness connectors -1- from plenum chamber.
- Disengage wiring harness (arrows) and move clear to one side.
- Disconnect two coolant hoses for heater core at engine (release retaining clamps on connecting flanges).





- Disconnect blue harness connector on Intake Manifold Tuning (IMT) valve; disconnect black harness connector for Intake Air Temperature (IAT) sensor on intake air elbow.
- Cut tie wraps and move wiring to side.
- Disconnect vacuum lines at vacuum booster -A-, at fuel pressure regulator -B- and at AIR solenoid valve T-connector -C- for combination valves.
- Remove bolts -1-, -2- and -3- at rear part of intake manifold.
- Disconnect hoses between vacuum booster and intake air elbow.
- Remove cruise control vacuum unit from bracket and detach at throttle plate.
- Remove harness connectors for camshaft adjustment.
- Disconnect wiring between EVAP canister purge regulator valve and throttle plate at throttle plate.
- Move disconnected hoses and wiring clear to one side.
- Remove intake air elbow.
- Disconnect heater core supply and return hoses at rear of engine.
- Disconnect accelerator pedal cable at throttle valve control module and at support bracket (do not remove accelerator pedal cable retainer). Move accelerator pedal cable clear to side.
- Disconnect harness connectors on right side of plenum chamber and move them clear.
- Cut cable tie on bracket for harness connectors.
- Pull lower parts of connectors out of bracket and move wiring clear.
- Vacuum line connections.





- Clamp off two hoses at hydraulic fluid supply line using 3094 hose clamps.
- Disconnect supply line (arrow) below left cylinder head.
- Place rag under connection to catch escaping fluid.





- Disconnect hydraulic pressure line at rear coolant line (left arrow).
- Disconnect hydraulic pressure line at right-side cylinder head (right arrow).





- Hold viscous fan pulley using 3212 spanner wrench and remove viscous fan using 3312 open-end spanner.

CAUTION: The viscous fan is mounted with a left-handed thread; turn clockwise to loosen (arrow).

- Carefully lift out viscous fan.





- To loosen ribbed belt, turn tensioner clockwise using 17 mm box wrench until two holes are aligned (arrows). Counterhold in position using 3204 drift.

CAUTION: Mark the running direction of the belt with a crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt.

- Remove ribbed belt.





- Disconnect ground connection (engine/cross member) from engine (upper arrow).
- Open bracket (lower arrows) for wiring for starter and generator at longitudinal member.
- Disconnect cables from starter and generator and move cables clear.





- Remove left and right-side exhaust pipes from exhaust manifolds (arrows).
- Remove spring-loaded bolts on mounting brackets for Three Way Catalytic Converters (TWC).
- Move exhaust system toward rear and off studs on exhaust manifolds.
- Remove starter and take it out toward rear between subframe and drive axle.

Vehicles with automatic transmission





- Remove 3 bolts (arrow) from torque converter (turn torque converter 1/3-turn [120°] each time).
- To remove engine, mount generator to bracket with one bolt.

Vehicles with air conditioning

CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.
- DO NOT open the air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending. Refrigerant lines kink easily.





- Detach A/C refrigerant lines from oil pan at front of engine.
- Place clean VW1306 receptacle or drain pan under engine.
- Remove engine coolant lines below oil filter.
- Place oil drain pan below oil filter.
- Remove oil filter and oil cooler.
- Remove A/C compressor (with refrigerant hoses attached) and hang up using wire.

All models





- Mark positions of mounts -1- and locating sleeves -2- on left and right-side engine mounts (bottom).
- Remove nuts -1- on left and right-side engine mounts.

Note: When installing, make sure that locating sleeves -2- engage again.

- Remove upper and lower engine/transmission bolts.





- Position 10-222A engine support bridge on bolted flanges of fenders.
- Engage 3147 engine support adapter in bolt hole in bell housing on transmission and connect to spindle of 10-222A engine support bridge.





- Attach 2024A engine sling at right-rear and left-front and secure.
- Push engine crane into position and attach to engine sling.

WARNING:
- To properly balance the engine assembly, install the hooks in the correct hole in the rail, exactly as shown in the illustration.
- Install mounting hooks and pins on the engine sling and secure them with the positioning lock.

Note: Check to make sure that all of the hoses and connections between the engine and transmission have been disconnected.

- Carefully pull engine out toward front.
- Guide engine out of engine compartment from front.

Vehicles with automatic transmission
- Secure torque converter in transmission to prevent it from falling out.