Removal and Installation
Engine, removing and installing
WARNING: The ignition must be switched OFF when:
- Disconnecting ignition wires.
- Disconnecting fuel injection system wiring.
- Connecting or disconnecting test equipment leads.
- Disconnecting battery.
- Washing the engine or engine compartment
CAUTION! BEFORE disconnecting the battery:
- Stop the engine.
- Ignition must be switched OFF (a/so applies when connecting the battery).
- Failure to do so may damage the Engine Control Module (ECM)
- Determine correct coding for the anti-theft radio.
CAUTION! Whenever working on fuel supply or fuel injection systems, always observe the following rules of cleanliness:
- Thoroughly clean fuel supply lines and hose connections and the surrounding area before disconnecting.
- Place removed components on a clean surface and cover. Use plastic sheeting or paper. Do not use fluffy rags that could leave lint.
- Install only clean components. Do not remove replacement parts from the packaging unto immediately before installing them. Do not use parts that have been stored without packaging (for example in too/ boxes, etc.)
- Avoid working with compressed air when the fuel system is open.
- Replace all tie wraps that were cut and install them in the same location from where they were removed.
CAUTION!: A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment
- DO NOT open air conditioning refrigerant circuit
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
Engine, removing and installing
Special tools and equipment:
- Drip tray VAG 1306
- Hose clamps 3094
- Pin wrench 3212
- Open-end wrench 3312
- Drift 3204
- Engine lifting appliance VAG 3033
- Workshop crane VAG 1202A
- Engine/transmission jack VAG 1383
Engine, removing
Note:
- Remove engine together with transmission from the front
- Obtain anti-theft radio code.
- Replace all cable ties detached or cut when removing the engine in the same position when installing.
- The battery is located behind a cover on the right side of the luggage compartment.
- With ignition switched off, disconnect battery ground strap.
- Unscrew grille on left side -arrow-, unclip on right side.
- Remove noise insulation.
- Remove both front wheels.
- Remove both front wheel housings.
- Remove front bumper behind wheel housings.
- Unbolt bumper on left and right sides.
Vehicles with headlight washers:
- Clamp off washer hose for headlight washers with clamp 3094.
- Disconnect hose to jets at bumper in right air intake grille.
- Disconnect hoses for headlight washers (in right grille).
WARNING! The cooling system is under pressure when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly.
- Open cap of coolant expansion tank.
- Place drip tray VAG 1306 under engine.
- Drain coolant from radiator (bottom left) -arrow-. Install drain hose if necessary.
- Open drain plugs -arrows- and drain coolant.
CAUTION! Dispose of used coolant properly.
- Disconnect coolant hose connection -arrow-.
- Remove radiator shroud at left and right sides -arrows
- Remove engine cover -arrows-
- Remove air intake duct for air cleaner -arrows-.
- Remove bracket for hydraulic oil lines -arrow-.
- Disconnect temperature sensor -1-.
- Remove long loop for hydraulic oil -arrows- and move aside.
- Disconnect connector -1- for pressure switch.
CAUTION! The A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.
- DO NOT open air conditioning refrigerant circuit
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
- Remove condenser and hang up with wire.
- Disconnect left and right headlights
- Disconnect connectors for left and right indicator lights.
Automatic transmission only
- Disconnect ATF lines for automatic transmission -arrows-.
All vehicles
- Remove coolant hose at upper right radiator -arrow-.
- Disconnect thermal switch -arrow-.
- Disconnect connectors at horns.
- Remove cover -1- in front of ABS unit.
- Disconnect connectors in front of ABS unit -arrows-.
- Remove bolt -arrow- on left and right sides.
- Remove left and right impact absorbers -arrows-.
- Disengage hood release cable.
- Remove air shroud bolts -arrows- on left and right sides.
- Remove air shroud with radiator.
- Remove hose -1-.
- Remove hose -2- to throttle body.
- Remove hose -1- from air cleaner by turning it in direction of arrow.
- Remove bracket for frequency valve -2- from air cleaner housing.
- Disconnect connector from mass air flow sensor -3-.
- Remove bolt -arrow- and remove air cleaner housing together with mass air flow sensor and air intake duct.
- Disconnect connector -1- from oil level sensor and move wiring aside.
- Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan with wrench 3312 (left hand thread).
CAUTION!
- Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt
- When installing a used ribbed belt be sure the belt runs in the right direction and is seated correctly on the belt pulleys.
- To loosen ribbed belt, turn belt tensioner with 19 mm wrench in direction of arrow until both holes are aligned. Insert drift 3204 to hold tensioner in position.
- Remove ribbed belt. Service and Repair
- Remove pulley of hydraulic pump using pin wrench 3212 to counter-hold.
Note: Be aware of washers behind belt pulley. Install washers again when pulley is reinstalled.
- Remove hydraulic pump from bracket and move it aside.
- Remove clamp for refrigerant line -arrow-.
CAUTION! The A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.
- DO NOT open air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
- Remove A/C compressor and hang up with wire. Watch out for centering dowels to locate A/C compressor on bracket.
Automatic transmission only
- Remove bolts -arrow- for bracket for ATF lines at engine.
All vehicles
- Remove torque support -arrows-.
- Disconnect connector -1- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
- Disconnect connector -2- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
- Disconnect connector -3- for right oxygen sensor and free wiring.
WARNING!
- Fuel lines are under pressure. Keep anything away that could ignite fuel or fumes.
- Before disconnecting fuel lines, clean connections.
- Cover connections with rag to protect against fuel spray.
- Disconnect fuel supply and return lines.
- Remove hose -2- and move it aside.
- Remove hoses -arrows- from coolant expansion tank
- Remove coolant expansion tank.
- Disconnect connector from coolant level sensor at expansion tank.
- Disconnect connector for left oxygen sensor -arrow- and set wiring aside.
- Remove coolant hose -1-.
- Disconnect connector -2-.
- Disconnect ground wire -3- at cylinder head.
- Disconnect connector -4-.
- Disconnect connector -5-.
- Disconnect connector -1- from Camshaft Position (CMP) sensor.
- Disconnect connector -2-.
- Disconnect connector -3-.
- Disconnect connector -3-.
- Disconnect connector -4- from ignition coils.
- Disconnect connector-6-.
- Disconnect connector -1- for knock sensor at cylinder bank 5-8.
- Disconnect connectors -arrows- from fuel injectors of cylinder bank 5-8 and set wiring harness aside.
- Disconnect connector for knock sensor at cylinder bank 1-4.
- Disconnect connectors from fuel injectors of cylinder bank 1-4.
- Remove clamp -arrow- from coolant line and set wiring harness aside.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
- Remove upper exhaust pipe bolts, left and right.
- Remove exhaust pipe bolts -arrows- at left from below.
- Remove exhaust pipe from retainer -arrow-
- Loosen double clamp -1- and push it forward.
- Carefully remove exhaust pipe.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
- From below, remove bolts-arrow between exhaust pipe and exhaust manifold.
- Remove exhaust pipe from retainer -arrow-.
- Loosen double clamp -2- and push forward.
- Carefully remove exhaust pipe with Three Way Catalytic (TWC) converter.
CAUTION! DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
- Disconnect cable -1- from generator.
- Disconnect cable -2- from generator.
- Remove bracket -3-.
- Remove bracket for protective cover.
- Remove oil filter.
- Disconnect ground cable -arrow-.
- Remove bracket for starter motor.
- Disconnect electrical wiring from starter motor.
- Remove starter motor.
Note: Before unbolting torque converter, mark alignment with drive plate.
- Remove bolts of torque converter-arrow (three bolts).
Tightening torque: 85 Nm (63 ft. lbs.)
If engine or transmission are replaced separately:
- With engine separated, turn crankshaft to TDC and align markings on torque converter and bell housing.
- Remove left and right engine mounts.
- Attach engine sling VAG 3033 at two engine lifting points shown.
- Position workshop crane VAG 202A and hook up sling VAG 3033.
WARNING!
- To properly balance the engine assembly, install the hooks in the correct notches of the sling, exactly as shown in the illustration.
- Assure that hooks are firmly connected with the lifting eyes.
- Carefully lift engine and transmission and remove toward front.
Engine, attaching to engine stand
- Engine holding fixture VW 540.
- Mount engine to engine stand using VW 540/1 holding fixture to repair stand VW 540.
CAUTION! DO NOT measure cylinder bore dimensions while cylinder block is mounted on the engine stand. The cylinder block is stressed and deformed by its own weight under these conditions and the measurements will not be accurate.
Engine, installing
CAUTION!
- DO NOT re-use fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once and are unreliable and may fail the second time. This includes, but is not limited to nuts, bolts, washers, circlips and coffer pins. Always follow the recommendations- replace these fasteners with new parts where indicated and any other time when deemed necessary by inspection.
- To prevent contact corrosion, use only approved nuts, bolts and washers, etc. These fasteners have a special coating and are identified by green coloring.
Install engine in reverse order of removal - but note the following:
- Check clutch release bearing for wear and replace if necessary.
There is no needle bearing in the crankshaft on vehicles with an automatic transmission.
- When installing an exchange engine with manual transmission, check for a needle bearing in crankshaft. Install one if not yet installed.
- Check that dowel sleeves for centering engine/transmission are installed in cylinder block; install if necessary.
- Check level of hydraulic fluid and fill up if necessary
- Fill cooling system.
- Install torque support without tension - use additional shims if necessary.
- Align engine by shaking engine before tightening engine mounts.
- Check oil level before starting engine.
- Check ATF level (automatic transmission).
Refer to Transmission and Drivetrain.
- After connecting battery, enter anti-theft code for radio Radio operating instructions
- Close windows fully using electric window switches.
- Operate all electric window switches again for at least one second in the "close" direction to activate "one-touch" opening and closing function.
- Set clock to correct time.
Tightening torques
- Engine/transmission attaching points (transmission flange shown)
Centering sleeves (A and B)
Torque Converter To Drive Plate: 85 Nm (63 ft. lbs.)
Right Engine Mount To Engine 45 Nm (33 ft. lbs.)
Generator To Engine
M10 40 Nm (30 ft. lbs.)
M8 25 Nm (18 ft. lbs.)
A/C Compressor To Bracket 25 Nm (18 ft. lbs.)
Bracket For Central Hydraulic Pump And A/C Compressor To Engine 25 Nm (18 ft. lbs.)
Exhaust Pipe To Exhaust Manifold 40 Nm (30 ft. lbs.)
Engine Mount To Body 50 Nm (37 ft. lbs.)
Wheel Bolt To Wheel Hub 120 Nm (89 ft. lbs.)