Engine, Removing And Installing

ENGINE, REMOVING AND INSTALLING

Special Tools, Testers And Auxiliary Items
VAG 1921 spring clip pliers
2024 A Lifting tackle
G 000 100 grease (vehicles with manual transmission)
VAG 1331 Torque wrench, 5 to 50 Nm range (4 to 37 ft lb)
VAG 1332 Torque wrench, 40 to 200 Nm range (30 to 150 ft lb)
Cable ties

Removal Notes
- Remove engine and transmission (as an assembly) in a forward direction
- Switch off ignition
- Disconnect battery ground strap. Note: Obtain anti-theft radio code first, before disconnecting battery
- When re-installing the engine, replace or re-install all cable ties (in the original position) which were opened or cut during engine removal

Removal
- Remove Air Cleaner housing complete with intake hoses

- Loosen power steering reservoir hose clamp

- Disconnect power steering hydraulic lines from engine carrier and transmission

- Disconnect power steering pump with bracket and lay to one side, hoses remain connected.

- Drain engine coolant

- Disconnect throttle cable at injection pump lever, remove mounting clip on support bracket and release throttle cable

- Disconnect Cold Start Accelerator cable

ALL Engines
- Remove lock carrier with attachments

- Remove radiator fan and shroud

Vehicles With A/C, Additional Information And Removal Instructions

CAUTION: Do NOT open the A/C circuit and thus allow the refrigerant to leak into the atmosphere.

NOTE: 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:
- Unbolt A/C fluid reservoir and allow to hang free

- Remove retaining clamp(s) from refrigerant lines

- Remove ribbed belt

- Remove hood lock carrier assembly





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

Vehicles With Manual Transmission
- Remove hydraulic clutch slave cylinder

- Disconnect Transmission Range selector mechanism from transmission





- Attach lifting tackle 2024 A 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 7

CAUTION: Secure all 2024A lifting tackle hooks and locating pins using lock pins.

NOTE:
The positions marked 7 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

Vehicles With Automatic Transmission





- Attach lifting tackle 2024A 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

CAUTION: The hooks and locating pins must be secured with locking pins.

NOTE:
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

ALL Vehicles
- Remove the front engine as an assembly

- 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 WV 540 adaptor bracket.

Installation Note. Engine installation is the reverse of the removal procedures. When installing, note the following:
- Check clutch release bearing for wear, replace if necessary
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft using G 000 100 grease
- Check whether the alignment dowels for centering the engine/transmission are installed in the cylinder block, install if necessary
- When lowering the power train assembly, ensure that there is sufficient clearance between the power train and drive shafts

Installation
- First tighten assembly mount right rear, then assembly mount left rear

- Loosen front engine mount on carrier, align stress-free by rocking the power train assembly and then retighten

All Engines
- Install hydraulic clutch slave cylinder

- Install selector mechanism

- Install power steering pump

- Install lock carrier with attachments

- Installing A/C compressor

Engines With Ribbed Belt Without Tensioner
- Install ribbed belt

- Filling with engine coolant

- Electrical connections and routing see Wiring Diagrams

- Check headlight alignment and adjust if necessary

- Adjust shift cables, if necessary

- Adjust Cold Start Accelerator cable

- Adjust throttle cable

Tightening Torques

Mounting Points:

Front Engine Mount:

Right Rear Engine Mount:

Left Rear Engine Mount: