Removing
Engine, removing and installing
Special tools, testers and repair equipment required
- V.A.G. 1306 Drip tray
- T10012 Engine bracket
- VW 313 Support clamp
- VW 540 Engine and transmission support
- 3180 Retainer
- V.A.G. 1202 A Workshop crane
- 2024 A Lifting tackle
- V.A.G. 1331 Torque wrench (5 - 50 Nm)
- V.A.G. 1332 Torque wrench (40 - 200 Nm)
- V.A.G. 1383 A Engine/transmission jack
- V.A.G. 1921 Spring-type clip pliers
- VW 457 Support rails
- 3300 A Engine support device
- 3283 Pressing-out appliance
- VAS 5085 Step ladder
- V.A.G. 1756 Angle wrench
- G 000 100 Grease
- Bolt M10 X 25 / 8.8
- Bolt M8 X 25 / 8.8
Removing
Note: - The engine is removed from underneath 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.
- 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 anti-theft code on vehicles with coded radio.
- With the ignition switched off, disconnect the battery Ground (GND) strap.
- Remove right-hand cover panels -1- on lock carrier and -2- above expansion tank.
- Remove left-hand cover panels -1- on lock carrier and -2- above battery.
- Remove cover panel above cylinder head cover and in front of intake manifold (if applicable).
- Remove intake air duct.
- Disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from mass air flow sensor.
- Disconnect connectors -3- from mass air flow sensor.
- Remove bolts -4- and -5-, and remove air cleaner housing.
- Remove battery.
- Remove battery platform (arrows).
Disconnect both selector cables at transmission as follows:
- Mark position of both selector cables with waterproof felt-tip pen -1-.
- 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 selector cables.
- Remove bolts (arrows), remove selector cable support bracket from transmission and place to one side.
- Remove both windshield wipers.
- Detach rubber seal from plenum chamber.
- Detach cover from plenum chamber and move clear toward windshield.
- Open cable duct on left side of engine compartment.
- Disconnect connector in cable duct and move wiring clear.
- Release retainer catch on left control module connector and disconnect connector from control module.
- Release control module wiring harness as far as engine.
- Disconnect connector below intake manifold.
- Unbolt Ground wire -1- on engine/transmission flange.
- Disconnect wires -3- and -4- from starter.
- Disconnect connector -2- and pull out of retainer.
- Disengage wires from retainer on starter and move wires to one side.
- Disconnect connector from charge air pressure sensor and unclip wire from charge air hose.
- Disconnect air hose from throttle valve control module.
- Disconnect connector from coolant temperature switch on coolant line and move wiring clear.
- Disconnect fuel supply line -1- and fuel return line -2- at the connection point by pressing the release tabs.
Note: Watch color coding of connectors when reconnecting fuel supply and return lines.
WARNING! Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
- Slacken ribbed belt by turning tensioning element in direction indicated (arrow).
Note: 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 refitted, 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, approx. 55 mm long). Connecting rod support 3090 can also be used.
- Detach intake air hose between air cleaner and turbocharger as follows:
- Disconnect connector at waste gate Bypass Regulator Valve -N75-.
1- Connection at air cleaner
2- Detach pressure control valve for crankcase breather -8- from hose.
3- Disconnect vacuum hose for air recirculation valve at connection on cylinder head.
4- Detach hose from waste gate Bypass Regulator Valve -N75- at intake air duct.
5- Detach hose from air recirculation valve at intake air duct.
6- Detach connection to active charcoal filter at non-return valve.
7- Detach connection between waste gate Bypass Regulator Valve -N75- and pressure unit for charge air pressure control.
8- Detach air intake hose at connection on turbocharger and remove hose.
- Remove cap from coolant expansion tank.
- Disconnect vacuum hose from intake manifold to T-piece in front of retainer in plenum chamber.
- Disconnect coolant hose to expansion tank in plenum chamber.
- Disconnect electrical connector at coolant pump.
- Unbolt coolant pump from fan cowl; leave coolant hoses connected.
- Remove both front wheels.
- Unbolt bracket for headlight range control in left wheelhousing (top); detach retainer from suspension link and disconnect electrical connector.
- Remove noise insulation panels (center, left and right) (arrows).
- Place drip tray V.A.G. 1306 below engine.
- Turn drain screw (arrow) on radiator counter-clockwise, if necessary install drain hose to connection.
- Disconnect bottom coolant hose at oil cooler (arrow) to drain off remaining coolant.
- Unbolt connecting line between left ....
- .... and right charge air coolers from longitudinal members and disconnect both hoses from charge air coolers.
- Remove connecting line.
- Disconnect connectors on starter and transmission.
- Remove positive connection on starter.
- Remove cooling line from transmission.
- Pull out retaining clip from coolant hose on radiator (bottom left) and disconnect coolant hose.
- Open hose retainer on radiator (bottom left) and remove coolant hose completely.
- Unbolt pump pulley (brace pulley with hexagon socket wrench).
- Place clean container under pump.
- Open spring clamp -3- on intake hose and disconnect hose.
- Disconnect expansion hose -4-.
Note: On vehicles with pressure switch, first disconnect connector and remove switch.
- Unbolt pump from bracket -1- and -2- (4 bolts).
- Remove coupling link nut from stabilizer bar.
- Remove upper nut on ball joint.
- Install ball joint splitter as shown in illustration and press out ball joint.
Note: To protect ball joint threads leave nut on a few turns.
- Remove bolts -1- for steering gear and bolts -2- for pendulum support.
- Unbolt bracket for line to hydraulic fluid reservoir at steering gear (right).
- Detach rubber mount at front exhaust pipe.
- Place engine/transmission jack V.A.G. 1383 A with universal support 1359/2 under subframe.
- Remove subframe bolts -3- and -4-.
- Lower subframe carefully.
- Unbolt heat shield for right-hand drive axle.
- Unbolt left and right drive axles from transmission flanges.
- Move drive axles clear toward rear of vehicle and tie them to bolts provided for this purpose on subframe.
- Remove front exhaust pipe.
Note: Do not bend the flexible connection on the front exhaust pipe more than necessary (not more than 10 degrees).
- Disconnect hoses and connectors from secondary air pump.
- Remove secondary air pump.
Vehicles with air conditioner:
- Disconnect connector on A/C compressor and move wiring clear.
WARNING! The air conditioner refrigerant circuit must not be opened.
- Detach retainers for refrigerant hoses.
- Unbolt A/C compressor -A-, lift clear and tie up on hood lock together with refrigerant hoses.
Note: Before installing compressor press sliding bush -B- back into hole.
- Using hose clamp 3094, clamp off pressure hose -1- to clutch slave cylinder.
- Pull out retainer toward the top (arrow) and disconnect pressure hose -1- from hose connector.
- Disconnect connector from reversing light switch.
Note: Do not depress clutch pedal.
The starter motor is removed in the illustration to give a clear picture.
- Disengage wiring harness from retainers and place to one side.
- Unbolt drive axle from transmission.
- Loosen engine/transmission assembly mount on engine side ...
- and on transmission side (about 2 turns only). 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
- Install engine/transmission jack V.A.G. 1383A to engine bracket and raise engine/transmission slightly.
- Unbolt engine/transmission mount on the engine side. (Use step ladder VAS 5085 for access to engine compartment from above.)
- Unbolt engine/transmission mount on the transmission side.
- Carefully lower the engine/transmission assembly.
Note: Check to make sure that all connections between engine and body have been detached.
The engine/transmission assembly must be carefully guided by a second mechanic while it is being lowered so as to avoid damaging the body panels.
- Remove bolts -1- and -2- from bracket on bevel box.
Note: The bracket cannot be removed.
- With transmission still in Position, remove bolt -1- (wrench width = 10 mm) and pull out small cover plate -2- toward the top.
Note: The transmission is removed in the illustration to give a clear picture.
- Remove bolts -1- to -8- on engine/transmission flange.
- Separate engine from transmission.