Removal
CAUTION:- 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 coffer pins.
- Always follow the recommendations in this information, replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.
- On vehicles equipped with an anti-theft radio, make sure you know the correct radio activation code before disconnecting the battery.
SPECIAL TOOLS
^ Spring Clip Pliers Tool No. VAG 1921, Or Equivalent.
^ Lifting Tackle Tool No. 2024A, Or Equivalent.
^ Torque Wrench Tool No. VAG 1331, Or Equivalent.
- 5 to 50 Nm range (4 to 37 ft. lbs.)
^ Torque Wrench Tool No. VAG 1332, Or Equivalent.
- 40 to 200 Nm range (30 to 150 ft. lbs.)
REMOVAL
1. Switch ignition off.
2. Disconnect battery Ground (GND) strap.
NOTE:
- Remove engine and transmission (as an assembly) in a forward direction.
- When re-installing the engine, replace or re-install all cable ties (in original position) which were loosened or cut during engine removal.
3. Remove air cleaner housing complete with intake hoses.
4. Loosen power steering reservoir hose clamp.
5. Disconnect power steering hydraulic lines from engine carrier and transmission.
6. Disconnect power steering pump with bracket and move to one side.
NOTE: DO NOT disconnect power steering hoses.
7. Drain engine coolant.
8. Disconnect accelerator pedal cable at injection pump lever, remove mounting clip on support bracket and release cable.
9. Disconnect cold start accelerator cable.
10. Disconnect fuel supply and return lines from injection pump.
11. Disconnect all wiring harness connectors and other electrical connections from engine as required.
12. Remove lock carrier with attachments.
13. Remove radiator fan and shroud.
14. On models with with A/C, proceed as follows:
a. Unbolt A/C fluid reservoir and allow to hang free.
b. Remove retaining clamp(s) from refrigerant lines.
c. Remove ribbed drive belt.
d. Remove A/C compressor bracket.
e. Remove A/C compressor and lay to one side with hood lock carrier arranged such that refrigerant lines -arrows- are not stressed.
NOTE: Do NOT open the A/C circuit and allow the refrigerant to leak into the atmosphere.
15. On models with manual transmission, disconnect clutch cable.
16. On all models, disconnect shift linkage from transmission.
17. Disconnect drive axles from transmission drive flanges.
18. Disconnect exhaust from turbocharger.
19. On models with manual transmission, attach engine sling as follows, then lift slightly using workshop crane (remove slack).
- Pulley end: 2nd hole in hook at position 1.
- Flywheel end: 2nd hole in hook at position 7.
NOTE:
- Secure all engine sling 2024A hooks and locating pins using lock pins
- The end of the cross bar marked with installation positions 1-4 points toward drive belt.
- Holes in the hooks are counted from the hook end.
20. On models with automatic transmission, attach engine sling as follows and lift slightly using workshop crane (remove slack).
- Pulley end: 2nd hole in hook at position 1
- Flywheel end: 2nd hole in hook at position 5
NOTE:
- Secure all engine sling 2024A hooks and locating pins using lock pins
- The end of the cross bar marked with installation positions 1-4 points toward drive belt.
- Holes in the hooks are counted from the hook end.
21. On all models, remove front engine mount as an assembly.
NOTE: Carefully guide engine/transmission assembly when lifting to avoid damage to body.
22. Lift engine/transmission assembly out toward the front.