Removal

ENGINE, REMOVING And INSTALLING:

Special Tools, Testers And Auxiliary Items:
^ VAG 1921 Pliers for spring type clips
^ 3227 Engine stand
^ VAG 1383 A Engine/transmission jack
^ 2024 A Lifting tackle
^ VW 540 Engine bracket
^ 3250 Support device
^ G 000 100 grease
^ VAG 1331 5 - 50 Nm (3.5 to 37 ft lb) Torque wrench
^ VAG 1332 40 - 200 Nm (30 to 148 ft lb) Torque wrench
^ Cable tie
^ VAG 1306 Drip tray

Engine Removal Notes:
^ Remove the engine downward together with the transmission.
^ Obtain the radio security code from the customer first before disconnecting the battery Ground strap.
^ Disconnect battery Ground strap with ignition switched OFF.
^ All cable ties which are opened or cut to remove the engine must be replaced in the same position when re-installing the engine.

WARNING: Fire hazard! Do NOT have anything in the area that can ignite fuel.

- Insert 3250 left and right support device to support the upper wishbone.
- Remove sound dampening tray.
- Drain engine coolant.

Vehicles 09.94 - on:
- Remove Radiator grille.

All Vehicles:



- Unscrew left and right mounting screws -1-.
- Tilt lock carrier and radiator out and forward -arrow-.
- Pull radiator coolant hoses off engine using VAG 1921 hose clip pliers.
- Pull connectors off thermoswitch and radiator tan.

Vehicles up to 12.95:



- Drive out left and right spreader clip pins -arrows- and unclip spreader clips from radiator bracket.

All Vehicles:
- Lift out radiator with fan, air guide and lock carrier.
- Unscrew speedometer drive at transmission.
- Unhook throttle cable from throttle body and support bracket.
- Remove mechanical clutch control cable (or hydraulic clutch slave cylinder)

Vehicles with Manual Transmission:
- Disconnect selector mechanism from transmission.

Vehicles with Automatic Transmission:
- Remove selector lever cable from transmission:

Vehicles with A/C, additional information:

WARNING! Do NOT open the A/C refrigerant circuit.

NOTE:
- To prevent damaging the condenser and refrigerant lines/hoses ensure that the lines and hoses are not stretched, kinked or bent.
- To facilitate removing and installing the engine without opening the refrigerant circuit:
- Remove A/C compressor and condenser and lay to one side so that the refrigerant lines/hoses are not stressed.

All Vehicles:
- Disconnect power steering pump lines from engine, drain fluid.
- Remove left-hand drive shaft and disconnect right-hand drive shaft at transmission.
- Remove front exhaust pipe with Oxygen sensor. Service and Repair
- Disconnect pressure and return noses from power steering.




- Bolt engine stand 3227 with 20 Nm (15 ft lb) to cylinder block.
- Carefully lift engine/transmission using VAG 1383 A engine/transmission jack.




- Unscrew 2 mounting bolts -arrows- from transmission mounting on sub-frame.
- Remove engine and transmission mounting central bolts on right and left in engine compartment.
- Remove engine with transmission downwards, when doing this, guide power steering fluid return hose.

NOTE: When lowering, carefully guide the engine/transmission assembly to prevent damage to the bodywork.