Engine, Removing
Notes:
^ The engine is removed from underneath together with the gearbox.
^ All cable ties, which are opened or cut open when removing the engine must be replaced in the same position when installing the engine.
^ Secure all hose connections with hose clamps of the same type as those fitted at the factory
^ V.A.G 1921 hose clip pliers are recommended when installing spring - type clips.
^ Make sure the connectors are correctly assigned; mark if necessary.
^ Obtain radio code on vehicles with coded radio.
^ With the ignition switched off, disconnect the battery Ground strap.
^ Remove engine cover from cylinder head cover.
^ Remove cover in front of intake manifold.
^ Disconnect air duct at bottom of right-hand longitudinal member (air duct leads to charge air cooler).
^ Remove noise insulation in the center and on left and right sides - arrows -.
^ Unbolt heat shield for right - hand drive axle.
^ Unbolt pendulum support.
^ Unbolt left and right - hand drive axles from gearbox flange.
^ Move left - hand drive axle toward rear of vehicle and secure in place by tying to anti- roll bar.
^ Remove front exhaust pipe.
Notes: Do not bend the flexible connection on the front exhaust pipe more than necessary (not more than 100)
^ Secure support rails 457/1 to subframe with bolt M8 x 25 (- B -). Also secure engine support device 3300A (- C -) to support rails 457/1 (arrows).
^ Press the engine forward.
Notes: Make sure not to damage the power assisted steering pipe.
^ Loosen right - hand 12 - point nut for drive axle. When doing this, the vehicle must be standing on its wheels.
^ Unbolt wheel.
^ Press out drive axle using special tool 3283.
Notes: Make sure there is enough clearance when pressing out the drive shaft.
^ Remove drive axle.
^ Place drip tray V.A.G 1306 below engine.
^ Remove cap from coolant expansion tank.
^ Turn drain screw - arrow - on radiator counter - clockwise. If necessary, fit drain hose to connection.
^ Disconnect bottom coolant hose from oil cooler- arrow - and allow remaining coolant to drain off.
^ Disconnect air hose - 4 - from air mass meter.
^ Unplug electrical connectors for air mass meter - 1 -.
^ Remove bolts - 2 - and - 3 - and take off air cleaner housing.
The air intake hose connection on turbocharger is detached as follows:
^ Disconnect vacuum hose - 1 - from air recirculation valve.
^ Disconnect hose from pressure control valve for crankcase breather - 2 -.
^ Unplug electrical connector from charge pressure control valve - 3 - - N75.
^ Disconnect hose - 4 - from charge pressure control valve - N75.
^ Disconnect hose - 5 - at bulkhead (hose leads from solenoid valve to turbocharger).
^ Remove solenoid charge pressure control valve from air intake hose and place it to one side on the engine.
^ Disconnect hose between activated charcoal filter and turbocharger on bulkhead.
^ Pull retainer off turbocharger connection and detach air intake hose.
^ Remove battery.
^ Remove battery platform - arrows -.
^ Unbolt Ground wire - 1 - on engine/gearbox flange.
^ Disconnect wires - 3 - and - 4 - from starter.
^ Unplug connector - 2 - and pull out of retainer.
^ Disengage wires from retainer on starter and move wires to one side.
^ Unplug connector - 1 - for electrical change - over valve on underside of bracket.
^ Unbolt bracket from intake manifold (- 2 - and - 3 -) and disengage dipstick tube - 4
^ Disconnect wire - 1 - from terminal 30/B+ on generator.
^ Unplug connector - 2 - from terminal D+.
^ Detach cable clip - 3 -.
Vehicles with air conditioner:
^ Unplug connector from a/c compressor.
All models
^ Remove coolant hose - 1 - (complete).
^ Disconnect wires/unplug connectors as follows:
2 - Knock sensor I - G61
3 - Road speed sender- G28 (center, gray)
4 - Knock sensor 11 - G66 6- Oil pressure switch - F1 - Take generator wire out of retainer.
^ Disconnect vacuum pipe - 5 - from intake manifold.
^ Unplug connector - 1 - for intake air temperature sender - G42 and connector - 4 -for throttle valve control part - J338 (under throttle valve control part).
^ Disconnect air hose - 2 - from throttle valve control part.
^ Disconnect vacuum hose - 3 - (for activated charcoal filter) from throttle valve control part.
^ Unplug connector from Hall sender (G40) - arrow -.
^ Disconnect vacuum pipe - 1 - from vacuum reservoir.
^ Unbolt vacuum reservoir - 2 - and detach it from the bracket.
^ Unplug connectors - 3 - from injectors and unclip support bar from fuel rail at points -4 - and - 5 -.
^ Unbolt Ground wire - 6 - between ignition coils 1 and 2.
^ Unplug connectors - 7 - from ignition coils.
^ Unplug connector from coolant temperature sender - G62 (on coolant hose flange on left of cylinder head).
^ Unplug connector from speedometer sender - G22 (on rear of gearbox).
^ Move pipes and hoses clear.
^ Disconnect the coolant hoses:
- On expansion tank (top and bottom)
- On cylinder head (top hose leading to radiator)
- On bulkhead (two hoses leading to heat exchanger for heater)
- On left of engine block, below cylinder head (hose joined to connection in upper coolant hose leading to radiator)
- On oil cooler (rear hose)
^ Disengage wiring harness from retainers and place to one side.
^ Mark threaded sections of both selector cables - 1 - with a permanent marker pen so that they can be installed in the same positions later.
^ Pull collar in direction of arrow - 2 - (toward ball joint) to compress spring, then turn collar clockwise (arrow - 3 - ) to lock in position.
^ Disengage both threaded sections.
^ Unclip clutch slave cylinder hose from selector cable support bracket - arrow -.
^ Unscrew bolts - arrows -, remove selector cable support bracket from gearbox and place to one side.
^ Remove clutch slave cylinder from gearbox and place to one side.
Notes:
^ Do not open the pipe system.
^ Do not depress the clutch.
^ Disconnect electrical wire from reversing light switch - F4.
^ Disengage wiring harness from retainers and place to one side.
^ Disconnect fuel supply line - 1 - and fuel return line - 2 - at the connection point by pressing the release tabs.
Notes: Check the colors of the connectors when connecting the fuel supply and return lines.
WARNING: The fuel system is under pressure! Before opening the system place a cloth around the connection, then release pressure by carefully loosening the connection.
^ Loosen ribbed belt by turning tensioning element in direction indicated (arrow).
Notes: Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when reinstalled, this can result in breakage. When installing the belt, ensure it is correctly seated in the pulleys.
^ Remove ribbed belt.
The tensioning element can be locked in position with a suitable punch (4.5 mm diameter, approximately 55 mm long). Conrod support 3090 can also be used.
^ Unscrew connecting pipe between both left and right crossmembers.
Right crossmember
^ Unscrew connector at both starter and transmission.
^ Unscrew B+ cable from starter.
^ Unscrew power steering fluid cooling line from transmission.
^ Remove cooling line retaining clip at lower left and remove coolant hose.
^ Open hose clamp at lower left of radiator and completely remove cooling line.
^ Unscrew pulley from power steering pump (counterhold with socket wrench).
^ Place clean container under pump.
^ Open spring clips - 3 - from intake hose and remove hose.
^ Remove flexible hose - 4 -.
Notes: For vehicles with pressure switch, remove connector first and unscrew switch.
^ Unbolt pump bolts - 1 - and - 2 - from bracket (4x).
^ Remove connector and hoses at secondary air pump.
^ Remove secondary air pump.
^ Unplug the two radiator fan connectors on the radiator cowl (bottom left).
^ Detach cowl from radiator (4 bolts) together with the two fans and remove by pulling downward.
Vehicles with air conditioner:
WARNING: The air conditioner refrigerant circuit must not be opened.
^ Detach retainers for refrigerant hoses.
^ Unbolt A/C compressor, lift clear together with refrigerant hoses (do not disconnect) and tie in place on hood lock.
^ Loosen engine/gearbox mounting (about two turns only) on engine side. Do not remove the bolts completely.
^ Loosen engine/gearbox mounting (about two turns only) on gearbox side. Do not remove the bolts completely.
^ Raise the vehicle.
^ Bolt engine bracket T10012 to cylinder block with securing nut and bolt (M10 x 25/8.8). Tighten to about 20 Nm.
^ Fit engine/gearbox jack V.A.G 1 383A to engine bracket and raise engine/gearbox slightly.
^ Unbolt engine/gearbox mounting on the engine side. (Use step ladder V.A.S 5085 for access to engine compartment from above.)
^ Unbolt engine/gearbox mounting on the gearbox side.
^ Carefully lower the engine/gearbox assembly.
Notes:
^ Check to make sure that all connections between engine and body, have been detached.
^ The engine/gearbox assembly must be carefully guided by a second technician while it is being lowered so as to avoid damaging the body panels.
^ Remove bolts - 1 - to - 8 - on engine/gearbox flange.
^ Separate engine from gearbox.