Removal

SPECIAL TOOLS, TESTERS AND AUXILIARY ITEMS
^ Spring Clip Pliers - Tool No. VAG 1921, or equivalent.
^ Lifting Tackle - Tool No. 2024A, or equivalent.
^ Grease G 000 100, or Equivalent (Vehicles With Manual Transmission)
^ Torque Wrench, 5 to 50 Nm range (4 to 37 ft. lbs.) - Tool No. VAG 1331, or equivalent.
^ Torque Wrench, 40 to 200 Nm range (30 to 150 ft. lbs.) - Tool No. VAG 1332, or equivalent.
^ Cable tie.

REMOVAL

NOTE:
- Remove engine and transmission (as an assembly) in a forward direction.
- Obtain anti-theft radio code first, before disconnecting battery.
- When reinstalling the engine, replace or re-install all cable ties (in the original position) which were opened or cut during engine removal.

1. Switch off ignition.
2. Disconnect battery ground strap.
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 lay to one side; hoses remain connected.
7. Drain engine coolant, refer to Cooling System.
8. Remove connecting line between Charge Air Cooler and intake manifold pressure line.
9. Remove lock carrier with attachments, refer to Body and Frame.
10. Remove radiator fan and shroud.
11. On Vehicles with A/C proceed as follows:

NOTE:
- Do NOT open the A/C circuit and allow the refrigerant to leak into the atmosphere.
- To prevent condenser and refrigerant line damage, ensure that none of the A/C lines and hoses are stretched, kinked or bent.
- To remove and install the engine without opening the refrigerant circuit:

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 hood lock carrier assembly.





e. Remove A/C compressor and lay to one side with hood lock carrier arranged such that the refrigerant lines -arrows- are not stressed.

12. On vehicles with manual transmission, proceed as follows:
a. Remove hydraulic clutch slave cylinder.
b. Disconnect transmission range selector mechanism from transmission.





c. Attach lifting tackle tool No. 2024A, or equivalent, and lift slightly using workshop crane (remove slack), as follows:
- Pulley end: 2nd hole in hook at position 1.
- Flywheel end: 2nd hole in hook at position 7.

NOTE:
- Secure all lifting tackle hooks and locating pins using lock pins.
- The positions marked 1 to 4 on the lifting bar must be located at the pulley end of the engine block.
- Hook holes are counted starting from the hook.

13. On models with automatic transmission, proceed as follows:





a. Attach lifting tackle 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:
- The hooks and locating pins must be secured with locking pins.
- The positions marked 1 to 4 on the bar must point towards the pulley end.
- The holes in the hooks are counted up from the hook.

14. On all models, remove the engine as an assembly as follows:
- Pry out the assembly in a forward direction.

NOTE:
- Carefully guide the assembly while lifting, to prevent damage to the bodywork.
- When working on the engine, secure the block to an engine stand using the tool No. VW 540, or equivalent, adaptor bracket.