Engine, Removing And Installing
Special tools, equipment, test and inspection devices; required accessories
- 2024 A Engine sling
- 3269 Engine support
- 3395 Engine bracket
- T10029 Spark plug connector tool
- VW 313 Holding fixture
- VAG 1202 Shop hoist
- VAG 1306 Drip pan for VAG 1202A
- VAG 1331 Torque wrench (5 - 50 Nm)
- VAG 1332 Torque wrench (40 - 200 Nm)
- VAG 1383 A Engine/transmission jack
- VAG 1921 Hose clip pliers
- VAS 5085 Ladder
- G 000 100 Lubricating grease (vehicles with manual transmission)
- Cable ties
Engine, removing
- Remove engine together with transmission from below.
- When installing, replace all cable ties that have been unfastened or cut during removal of engine at same location.
Note: As work progresses, it will be necessary to disconnect the battery ground strap. Therefore, please check whether a coded radio device has been installed. If so, it may be necessary to obtain the radio anti-theft protection code in advance.
- With ignition switched off, disconnect battery ground strap.
- Pull spark plug boots with Installation Tool T10029 and detach ignition cables.
- Remove engine cover.
- Remove battery and battery tray.
- Remove air filter assembly.
- Remove supply hose -l- (with white marking) and return hose -2- (with blue marking) and catch fuel that flows out with a cleaning rag.
Note: Squeeze the tabs on the hose clamps together.
WARNING: The fuel system is pressurized. Before opening the system, place a clean rag around the connection. Then reduce pressure by carefully and slowly loosening the connection.
- Plug lines to prevent contamination of fuel system.
- Remove center, left and right side sound damping tray:
- Remove "V" ribbed belt.
- Remove power steering pump from its mount and set aside; leave hoses connected:
- Remove mounting brackets for power steering pressure line.
Vehicles with air conditioning
- Observe additional instructions and installation operations.
Vehicles with manual transmission
- Remove shift linkage from transmission.
- Remove hydraulic clutch slave cylinder.
Vehicles with automatic transmission
- Remove selector lever cable from transmission:
Continuation for all vehicles
- Remove front bumper.
- Put lock carrier into service position.
- Remove intake pipe - top section.
- Disconnect vacuum and vent hoses from engine.
- Remove/disconnect and expose all electrical lines from transmission, alternator and starter.
- Disconnect plug connections on following components:
- Ignition Coil -N152-
- After-Run Coolant Pump -V51 -
- Camshaft Position (CMP) Sensor -G40-
- Cylinder 1, 4, 5, 6 Fuel Injector -N30- -N33-, -N83-, -N84-
- Engine Coolant Temperature (ECT) Sensor G62-
- Engine Speed (RPM) Sensor -G28-
- Knock Sensor (KS) 1 -G61 -
- Knock Sensor (KS) 2 -G66-
- Heated Oxygen Sensor (H02S) 1 -G39-
- Oxygen sensor 2 -G130-
Installation locations:
- Remove/disconnect and uncover from engine any additional electrical lines that may be necessary.
- Disconnect vacuum and vent hoses from engine.
- Drain coolant.
- Remove radiator coolant hoses from engine with pliers for spring clamps VAG 1921.
- Remove front exhaust pipe.
- Remove dust boot for inside right constant velocity joint from engine.
- Remove right and left drive axles from transmission.
- Remove rocker bracket -arrows-.
- Enlarge slot of engine bracket 3395 as shown to dimensions:
- a - 32 mm
- b - 27 mm
- Insert engine bracket 3395 into engine/transmission jack VAG 1383 A.
- Attach engine bracket 3395 to engine block and tighten to 40 Nm with retaining nuts -1-
- Slightly raise engine and transmission with engine/transmission jack VAG 1383 A.
- Remove support on engine side from engine bracket -arrows- from above.
Note: Use ladder VAS 5085 to remove retaining bolts.
- Remove support on transmission side from transmission bracket -arrows- from above.
- Carefully lower engine together with transmission.
Note: When lowering the engine together with transmission, it must be guided carefully in order to prevent damage to the structure.
Engine, attaching to engine stand
In order to carry out assembly work, the engine with engine bracket 3269 must be attached to clamping stand VW 313 of the mounting stand.
- Remove transmission from flange.
Vehicles with automatic transmission
- After separating engine from transmission, protect torque converter from falling out.
Continuation for all vehicles
- Bolt engine bracket 3269 to engine block.
- Attach engine support 2024 A as follows and lift engine out of engine/transmission jack with shop hoist.
- Vibration damper side: 4th hole of perforated bar in Position 1
- Flywheel side: 4th hole of perforated bar in position 8
CAUTION: Use retainer pins on the hooks and aligning pins.
Notes:
- The alignment positions of the support bracket marked 1-point to the belt pulley.
- Begin counting the holes in the perforated bars starting at the hook.
- Using shop hoist VAG. 1202 A, place engine in clamping stand VW 313.
Engine, installing
Installation is in reverse sequence; in doing so, please observe the following:
Vehicles with manual transmission
- Check clutch release bearing for wear, replace if necessary.
- Slightly lubricate clutch release bearing and splines of input shaft with G 000 100 (do not lubricate guide sleeve for release bearing).
Vehicles with automatic transmission
- Only use nuts that are approved for spare parts program to attach torque converter to drive plate.
Continuation for all vehicles
- Check if locating sleeves for centering engine/transmission are present in engine block, replace if necessary.
- When installing major assembly, make sure there is free movement with drive axles.
- When installing engine/transmission assembly, make sure there is free movement with assembly support and radiator.
- Align assembly support for engine and transmission.
Tightening specs, assembly support.
Vehicles with manual transmission
- Install hydraulic clutch slave cylinder
- Install shift linkage:
- Adjust shift cable, if necessary.
Vehicles with automatic transmission
- Replace E-clip on stop of selector lever cable.
- Install selector lever cable on transmission, adjust if necessary.
Continuation for all vehicles
- Install drive axles.
- Install dust boot for inside right constant velocity joint.
- Install front exhaust pipe with catalytic converter.
- Install intake pipe-top section.
- Install power steering pump.
- Install "V" ribbed belt.
Electrical connections and cable routing:
- Install center, left and right sound damping tray:
- Fill with coolant.
- Install air filter assembly.
- Check headlight adjustment; correct if necessary.
Repair Manual, Maintenance
- Test drive and check DTC memory.
- Adjust control unit for engine electronics to throttle valve control unit (basic settings).
- Read readiness code.
- If (DTC) memory was erased or engine control unit was disconnected from continuous positive power supply, you must regenerate readiness code.
Engine and transmission supports, aligning
CAUTION: Before loosening the bolts the assembly must be secured with bracing unit 10-222A.
Engine support
- a=14.0 mm
- b=10.0 mm minimum
- Both bolt heads must terminate flush with edge -c-.
Transmission support
Edges -a- and -b- must be parallel to each other.
Engine and transmission mounts
Torque specifications (Part 1 of 2)
Torque specifications (Part 2 of 2)
Engine Assembly
1 - 40 Nm + additional 1/4 turn (90 degrees)
2 - 25 Nm
3 - 60 Nm + additional 1/4 turn (90 degrees) 1)
1) Replace bolts
Transmission assembly
1 - 40 Nm + additional 1/4 turn (90 degrees) 1)
2 - 25 Nm
3 - 60 Nm + additional 1/4 turn (90 degrees) 1)
1) Replace bolts
Rocker bearing
Note: The bolts must not be reused.
CAUTION: The air conditioning coolant circuit must not be opened.
Note: To prevent damage to the condenser and to the refrigerant lines and hoses, make sure that the lines and hoses are not stretched, kinked or bent.
To remove and install the engine without opening the refrigerant circuit:
- Remove mounting bracket(s) of refrigerant lines.
- Remove "V" ribbed belt.
- Remove air conditioning compressor:
- Attach air conditioning compressor to body in such a way that refrigerant lines and hoses are not stressed.
Note: Protect the bumper against damage with adhesive tape.