Engine, Removing And Installing
Engine, Removing And Installing
Special tools and equipment
^ 2024 A Engine sling
^ T1001 2 Engine bracket
^ VW313 Support clamp
^ VW 540 Engine / Transmission support
^ V.A.G 1202 A Workshop crane
^ V.A.G 1306 Drip tray
^ V.A.G 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft. lbs.) or equivalent
^ V.A.G 1332 Torque wrench 40 to 200 Nm (30 to 148 ft. lbs.) or equivalent
^ V.A.G 1383A Engine/transmission jack
^ V.A.G 1921 Spring clip pliers or VAS 5024 tool for spring clamps
^ Step ladder (not shown)
^ MSO2 grease (manual transmission, only) (not shown)
^ Bolt M10 X 25/8.8 (not shown)
^ Cable ties (not shown)
Engine/transmission, removal notes
CAUTION:
- Obtain radio anti-theft code from the customer BEFORE disconnecting the battery Ground strap.
Note:
- Remove the engine and transmission as an assembly in a downward direction.
- All cable ties which are opened or cut open to remove the engine, must be replaced in the same position when reinstalling the engine.
- Ensure ignition is switched OFF then disconnect battery Ground strap
- Remove engine cover.
- Remove battery and battery bracket
- Remove Air Cleaner
WARNING:
- Fire Hazard! Do NOT have anything in the area that can ignite fuel!
- The fuel system is under pressure, therefore place a cloth over the connection before the hoses are disconnected.
- Remove fuel supply hose -1- (with white mark) and return hose -2- (with blue mark) and catch any fuel with a clean cloth.
- Seal lines so fuel system is not contaminated by dirt etc.
Vehicles with A/C
- Observe additional information and removal instructions.
- Remove power steering reservoir from battery support but do not loosen hoses.
- Tie reservoir to lock support
Vehicles with manual transmission
- Disconnect shift linkage from transmission.
- Disconnect all electrical wiring from transmission, Generator and starter and move to one side.
- Remove hydraulic clutch slave cylinder:
Vehicles with automatic transmission
- Remove Range selector lever cable from transmission:
All vehicles
- Remove intake manifold upper section:
- Disconnect Secondary Air Injection pump -V101 from bracket and remove.
- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Pull off/disconnect all other electrical connections from engine as necessary and lay to one side.
- Remove sound dampener tray:
- Remove ribbed belt.
- Remove power steering pump with bracket and lay to one side; hoses remain connected.
- Unscrew mounting clamps for power steering pressure lines.
- Remove right hand inner CV joint protective cover from engine if installed.
- Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission.
- Drain coolant.
- Remove hoses from radiator to engine using pliers V.A.G 1921 or VAS 5024.
- Remove auxiliary fan on right side of vehicle, if applicable.
- Remove pendulum support bolts (arrows).
- Remove front exhaust pipe with catalyst.
- Remove bracket for coolant hose under engine block.
- Mount engine bracket T10012 using threaded hole.
- Install engine bracket T100/12 in V.A.G 1383 A engine/transmission jack.
- Attach engine bracket T10012 using fastening nut and screw M10 X 25/ 8.8 with approx.
Tightening torque: 40 Nm (30 ft. lbs.)
- Carefully lift engine and transmission using V.A.G 1383 A engine/transmission jack.
- Remove bolts (arrows) from the top (from the engine mount).
Note:
- Stand on ladder to reach mounting bolts.
- Remove bolts (transmission side) from transmission mount (arrows) from the top.
- Carefully lower engine/transmission assembly.
Note:
- Carefully guide the engine/transmission assembly while lowering to prevent possible bodywork damage.
- Guide power steering pressure line past transmission when removing engine/transmission assembly.
Engine to assembly stand, attaching
Note:
- To work on the engine, secure it to the VW 313 assembly stand support clamp using the VW 540 engine/transmission bracket.
Work sequence
- Remove transmission.
Vehicles with automatic transmission
- Attach torque converter to prevent it from falling out.
All vehicles
- Attach 2024A lifting tackle with 2024 Al1 extension as follows and lift out from engine/transmission jack V.A.G 1383/A using workshop crane:
- Pulley end: 3rd hole in hook at position 2
- Flywheel end: 3rd hole in hook at position 8
WARNING:
- Secure all hooks and locating pins with locking pins.
Note:
- Ensure that positions marked 1 to 4 on the bar are towards the pulley end.
- Count the holes in the hooks up from the hook.
- Secure engine to VW 313 support clamp using VW 540 engine/transmission bracket.
Installation notes
Installation is the reverse of the removal sequence.
- During installation note the following:
- Check whether engine/transmission centering dowels are installed in engine block, install if necessary.
- Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).
Vehicles with manual transmission
- Check that clutch disc is centered.
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing and splines on input shaft with MS02 grease (Do not grease release bearing guide).
Vehicles with automatic transmission
When replacing nuts that secure torque converter to drive plate, only use approved ones from the VW parts program.
All vehicles
When installing the engine/transmission assembly, ensure sufficient clearance to front subframe, driveshafts and radiator.
While installing, guide the power steering pressure line past the transmission.
Do not stress the engine and transmission mounting points during installation (aligned parallel to each other)
Aligning engine and transmission mounts.
Vehicles with manual transmission
- Install hydraulic clutch slave cylinder
- Install shifter mechanism
- If necessary adjust shifting cables:
Vehicles with automatic transmission
- Replace selector cable anchorage locking washer.
- Install Transmission Range selector cable on transmission, adjust if necessary:
All vehicles
- Install left-hand drive shaft and reconnect right hand drive shaft at transmission:
- Install right hand inner CV joint protective cover on engine, if equipped.
- Install front exhaust pipe with catalyst.
- Install power steering pump.
- Install Secondary Air Injection pump -V101- on bracket.
- Install intake manifold upper section
- Adjusting accelerator cable.
- Install ribbed belt.
- Check electrical connections and wire routing:
- Fill system with engine coolant, Refer to Cooling System.
- Install sound dampening tray:
- Test drive and check DTC memory:
If malfunctions occur:
- Display Readiness code:
- Match Engine Control Module to Throttle Control Module:
- Check Readiness code:
Readiness code must be reset if Engine Control Module (ECM) -J220- is replaced or subjected to low voltage with ignition on.
Engine and transmission mounts, aligning
CAUTION:
- Engine and transmission must be supported by 10-222A engine support bridge before loosening bolts.
Engine mount assembly
a = 14.0 mm (0.55 in.)
b = minimum 10.0 mm (0.40 in.)
Bolt heads -1- must align with edge of mount -c-.
Transmission mount assembly
Edges -a- and -b- must be parallel.
Tightening torques
Engine/transmission mounts Tightening torques
Engine mount assembly
1. Mount to body 1)
- 40 Nm (30 ft. lbs.) + 90° (1/4 turn)
2. Mount/bracket to body
- 25 Nm (18 ft. lbs.)
3. Mount to engine bracket 1)
- 60 Nm (44 ft. lbs.) + 90° (1/4 turn)
1) Always replace
Transmission mount assembly
1. Mount to body 1)
- 40 Nm (30 ft. lbs.) + 90° (1/4 turn)
2. Mount to body
- 25 Nm (18 ft. lbs.)
3. Bearing on transmission case 1)
- 60 Nm (44 ft. lbs.) +90° (1/4 turn)
1) Always replace
Pendulum support
1. Pendulum support to transmission 1)
- 40 Nm (30 ft. lbs.) + 90° (1/4 turn)
2. Pendulum support to transmission 1)
- 40 Nm (30 ft. lbs.) + 90° (1/4 turn)
3. Pendulum support to engine/transmission 1)
- 20 Nm (15 ft. lbs.) +90° (1/4 turn)
1) Always replace