Removing and Installing
Special tools and equipment
- 3147 Transmission support
- 2024A Lifting tackle
- 10-222A Support device with legs 10222A/1
- VW313 Support clamp
- VW 540 Engine and transmission support
- VW540/1B Supplementary kit
- V.A.G 1383A Engine/transmission jack
- T10062 Support
- V.A.G 1306 Drip tray
- V.A.G 1331 Torque wrench (5-50 Nm)
- V.A.G 1332 Torque wrench (40-200 Nm)
- VAS 5024 Assembly tool for spring-type clip
- G 000 100 Grease (vehicles with manual transmission)
- Cable tie
Removing
The engine is removed forward without the transmission.
- First check whether a coded radio is fitted. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
Note: All cable ties, which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
- Unbolt power steering hydraulic oil cooling line -arrows- and ensure it is free. Do not open hydraulic oil circuit.
- Drain coolant.
- Remove lock carrier with attachments: Removal and Replacement
- Remove ribbed belt.
- Remove power steering suction and pressure lines at power steering pump:
Vehicles with air conditioner
- See additional information and removal instructions.
Continued for all vehicles
- Remove air cleaner upper part:
- Remove intake manifold cover.
Vehicles with cruise control system
- Remove vacuum unit for cruise control system.
Continued for all vehicles
- Disconnect throttle cable at throttle valve control part cable disc and support bracket -arrows- (do not remove locating clip on support bracket).
- Disconnect fuel supply and fuel return lines at fuel rail.
WARNING!: Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Remove inter-connecting coolant, vacuum and intake hoses on engine.
- Remove coolant system expansion reservoir and place to one side.
- Pull off/disconnect all electrical connections as necessary from engine and place to one side.
- Remove starter.
- Remove intake air elbow.
- Remove upper engine/transmission securing bolts.
- Remove lower securing nuts for left and right hand engine mountings.
Vehicles with automatic transmission
- Separate torque convertor from drive plate (3 securing nuts).
Note: After removing the engine, secure the torque converter against falling out.
Continued for all vehicles
- Unbolt torque reaction support at oil pan and secure it to support T10062 with two bolts.
- Raise engine with engine/transmission jack V.A.G 1383 A and support T10062 in order to be able to remove lower engine/transmission connecting bolts.
- Remove lower engine/transmission connecting bolts and lower assembly.
- Assemble support device 1 0-222A as shown.
- Attach transmission support 3147 to transmission bell housing bolt hole (shown in illustration with engine removed).
- Attach lifting tackle 2024 A as follows and lift slightly with workshop crane V.A.G 1202 A:
Pulley end: 2nd hole in hook at position 2
Flywheel end: 4th hole in hook at position 8
WARNING!: The hooks and locating pins must be secured with locking pins-arrows-.
Note:
- The positions marked 1-4 on the bar must be toward the pulley end.
- The holes in the hooks are counted up from the hook.
- Lift out engine forward.
Note: Guide the engine carefully when lifting out, to prevent damage to the bodywork.
Securing engine to engine stand
Special tools and equipment
- VW 540 Engine and transmission support bracket
- VW 540/1 B Supplementary kit
When working on the engine it should be secured to the engine stand using engine bracket VW 540 and supplementary kit 540/1 B.
- If necessary, drill out hole in securing plate of VW 540 (arrow) with a 15mm bit.
- For right-hand lower securing point (arrow) use a commercially available M12 x 160 bolt with a tensile strength of 8.8.
Installing
Install in reverse order but note the following:
Vehicles with manual transmission
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing and splines on input shaft with G 000 100 grease (do not grease release bearing guide sleeve).
- Ensure that intermediate plate is correctly positioned on engine.
Continued for all vehicles
- Check whether dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
- Align engine mountings stress-free by rocking engine.
- Replace engine mounting self-locking nut 1-.
Note: When lowering the engine the engine mounting pin -2- must engage in the subframe.
- Install starter.
- Install engine/transmission connecting bolts.
Note: Tightening torques.
- Install air conditioner compressor:
- Install power steering suction and pressure lines to power steering pump:
- Install ribbed belt.
- Install lock carrier with attachments: Removal and Replacement
- Install front bumper:
- Install front left and right-hand exhaust pipes, exhaust manifold, front exhaust pipe with catalyst and attachments.
- For vehicles without Electronic Power Control (EPC), adjust throttle cable.
- Check electrical connections and routing:
- Electrical Wiring Diagrams, Troubleshooting & Component Locations binder Fill with coolant.
- Carry out a test drive and check DTC memory:
- Match engine electronics control module to throttle valve control module:
- For vehicles with automatic transmissions, adapt transmission control module:
- Check headlight adjustment and adjust if necessary:
Tightening torques
M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
in variation of this
Starter to transmission 65 Nm
Additional information and removal instructions for vehicles with air conditioner
WARNING!: The air conditioner refrigerant circuit must not be opened.
Note: To prevent damage to condenser also to the 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 retaining clamp(s) from refrigerant lines.
- Remove air conditioner compressor:
- Secure air conditioner compressor to body so that refrigerant hoses/lines are relieved.