Engine: Service and Repair

NOTE: On air bag equipped vehicles, refer to Air Bags (Supplemental Restraint Systems), Service Precautions. Also refer to Air Bag(s) Arming and Disarming.

NOTE:
^ The engine is removed from above, after being separated from the transmission.
^ 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.

CAUTION: Determine correct radio anti-theft coding before disconnecting the battery.

REMOVAL

- Disconnect battery Ground (GND) strap.





- Remove 7 fasteners for undertray (arrows).
- Disconnect undertray mounting bracket from engine mount.





- Drain coolant from engine at drain plug (arrow).
- Drain coolant from radiator using drain plug at bottom left of radiator.





- Disconnect wiring at ballast resistor for radiator coolant fan and at ground point (arrow) on long member, and lay to one side.
- Remove 3 screws from coolant fan housing assembly at top of radiator.
- Remove fan housing assembly.





- Remove stabilizer brace from rear of engine compartment (arrows, top left).
- Disconnect intake air duct from intake manifold.
- Disconnect intake air duct from Mass Air Flow (MAF) sensor.
- Lift and push back intake air silencer and unclip both crankcase ventilation valves from silencer.
- Remove intake air silencer.
- Disconnect harness connectors from MAF sensor and Idle Air Control (IAC) valve.
- Remove EVAP canister purge regulator valve from MAF sensor bracket.





- Disconnect fuel supply and return lines.
- Disconnect vacuum lines from Intake Manifold Tuning (IMT) valve.
- Blue line from below
- Green line from front
- IMT valve is located behind and below EVAP canister purge regulator valve.





- Remove covers for fuel injection lines on left and right sides.
- Disconnect fuel injector harness connectors and set aside along with covers.





- Unclip upper section of air cleaner housing.
- Disconnect pre-heating hose and lower section of air cleaner housing, and remove.





- Disconnect harness connectors from connector bracket (next to engine compartment bulkhead).
- Remove tie wraps and straighten out wiring.
- Disconnect bracket for accelerator pedal cable sleeve from connector bracket.
- Disconnect coolant hoses that pass through bulkhead to heater core.





- Disconnect and expose accelerator pedal cable.
- Disconnect line from EVAP solenoid valve to throttle valve at throttle body.
- Disconnect ground strap from intake manifold (below accelerator pedal cable).
- Disconnect vacuum line brake booster at intake manifold.
- Disconnect vacuum line from EVAP canister purge regulator valve at throttle body.





- Disconnect harness connectors from Camshaft Position (CMP) sensor and Engine Coolant Temperature (ECT) sensor.
- Disconnect ignition coil harness connectors.
- Disconnect vacuum line from IMT valve.
Color: blue





- Clamp off supply line to power steering vane pump using special tool 3094, Snap-On YA 2850, or equivalent.
- Disconnect hose from pump bracket.
Use rag to absorb any spills.
- Remove cover for ribbed belt.





- Loosen ribbed belt as shown, and insert drift 3204 to secure belt tensioner.
- Remove ribbed belt.
- Remove coolant hose between engine and radiator on left side, and disconnect hose on right side.





- Disconnect pressure line from power steering pump (arrow).
Use rag to absorb any oil spills.





- Disconnect harness connectors from Throttle Position (TP) sensor and ECT thermal switch (arrows).





- Disconnect harness connectors for Heated Oxygen Sensor (HO2S), oxygen sensor heater and knock sensor (arrows).





- Disconnect battery positive (+) cable.
- Remove cable brackets on battery bracket and engine block.
- Disconnect connectors.
- Move cable to one side.





- Disconnect cooling air duct to generator (arrows).
- Disconnect engine to body ground strap (arrow, top left).





- Loosen bolts holding front engine mount at engine and crossmember (arrows).





- Disconnect A/C and coolant hose brackets at front of engine oil pan (arrows).
- Disconnect coolant hose between coolant line and radiator (below and to right).
- Remove oil filter.





- Disconnect and remove oil cooler behind oil filter.
- Disconnect coolant line.
- Disconnect harness connectors for A/C clutch (single) and for vehicle speed sensor (double).
- Open cable straps and lay wiring to one side.





- Loosen and remove A/C compressor from engine (arrows).
Lines remain connected.

CAUTION:
^ Disconnect brackets and support points only.
^ DO NOT open the air conditioning refrigerant circuit
^ Refrigerant lines kink easily.
^ The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment

- Carefully secure A/C compressor off to one side with wire.





- Disconnect exhaust pipes from exhaust manifolds (three bolts on each pipe, arrows).
- Remove both front bolts from engine crossmember (arrows,

WARNING: BE PREPARED. THE CROSSMEMBER WILL SUDDENLY DROP APPROXIMATELY 3/8 INCH AFTER REMOVING THE FRONT BOLTS.





- Remove both exhaust pipes complete with Three Way Catalytic Converters (TWC).
- Remove starter.
- Unfasten steering shaft cover at right at transmission
- Unfasten starter bolts all the way back to the steering shaft
- Working through starter opening, remove 3 torque converter mounting bolts.





- Remove upper and lower engine-to-transmission mounting bolts.





- Support transmission using engine support bridge 10-222A, suspension fixture 10-222 A-2, and engine support adaptor 3147.
- Remove nut on right side engine mount.





- Attach engine sling 2024A to right-rear and left-front of engine, and secure.

NOTE: In order to balance the engine using its center of gravity the rail holes of the engine sling must be arranged as illustrated.

- Attach workshop crane to engine sling.
- Lift engine slightly.





- Remove front engine support from long member.
- Carefully lift engine while turning engine support bridge 10-222A until clear of right engine mount.
- Carefully pull engine forward until it is completely clear.
- Lift out starter after engine has been separated from transmission.
- Lift engine up and out.





MOUNTING ENGINE CYLINDER BLOCK TO ASSEMBLY STAND
- Mount engine to stand using engine holder VW540 and spacers VW540/1A.

CAUTION: DO NOT measure cylinder bore dimensions while the cylinder block is mounted on the assembly stand. The cylinder block is stressed and deformed by its own weight under these conditions, and the measurements we not be accurate.

INSTALLATION

WARNING:
^ DO NOT RE-USE ANY FASTENERS THAT ARE WORN OR DEFORMED IN NORMAL USE.
^ SOME FASTENERS ARE DESIGNED TO BE USED ONLY ONCE, AND ARE UNRELIABLE AND MAY FAIL IF USED A SECOND TIME. THIS INCLUDES, BUT IS NOT LIMITED TO, NUTS, BOLTS, WASHERS, CIRCLIPS AND COTTER PINS. ALWAYS FOLLOW RECOMMENDATIONS
^ REPLACE THESE FASTENERS WITH NEW PARTS WHERE INDICATED AND ANY OTHER TIME IT IS DEEMED NECESSARY BY INSPECTION.

The engine is installed in the reverse order of removal, with the addition of the following special conditions and steps:
- Replacement short block assemblies are supplied without a pilot sleeve in crankshaft. Install the sleeve before installing the driveplate.
- Make sure that the engine-to-transmission alignment sleeves are properly installed in the cylinder block. Install the sleeves if necessary.
- When attaching the engine to the transmission, be careful to avoid damaging engine speed sensor.

During Engine Installation
- Shake engine to relieve any pre-load or tension between engine and mounts before tightening engine mounts.
- Observe tightening torque specifications.

After Engine Installation
- Align exhaust system without tension. Refer to Exhaust System.
- Connect harness connectors at bracket on engine compartment bulkhead.
- Re-install all cut or loosened cable ties in original locations.
- Check oil levels in engine and transmission.
- Fill with coolant. Refer to Cooling System.
- Tighten the following components to:
- Engine To Transmission:
8 mm Bolts 25 Nm (18 ft. lbs.)
10 mm Bolts 45 Nm (33 ft. lbs.)
12 mm Bolts 65 Nm (48 ft. lbs.)
- Torque Converter To Driveplate 35 Nm (22 ft. lbs.)
- Left Engine Support To Side Member 45 Nm (33 ft. lbs.)
- Right Engine Support45 Nm (33 ft. lbs.)
- Generator (GEN) To Mounting Bracket:
8 mm Bolts 25 Nm (18 ft. lbs.)
mm Bolts 10 mm Bolts 45 Nm (33 ft. lbs.)
- Three Way Catalytic Converter To Exhaust Manifold25 Nm (18 ft. lbs.)
- A/C Compressor To Mounting Bracket25 Nm (18 ft. lbs.)