Removing and Installing
Engine, removing and installing
Special tools and equipment
^ 3147 Transmission support
^ 10-222A/2 Additional hooks
^ 2024 A Lifting tackle
^ 10-222A Support device with legs 10222A/1
^ VW313 Support clamp
^ VW 540 Engine and transmission bracket
^ VAG 1306 Drip tray
^ VAG 1331 Torque wrench (5 to 50 Nm) or equivalent
^ VAG 1332 Torque wrench (40 to 200 Nm) or equivalent
^ VAS 5024 Installation tool for spring-type clips
^ VAG 1202 Workshop crane or equivalent
^ G 000 100 Grease (vehicles with manual transmission)
^ Cable tie
^ VAG 1383A Engine/transmission jack
^ T10062 Support
Removing
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
Note:
^ The engine is removed forward without the transmission.
^ All cable ties, which are opened or cut open when removing the engine, must be replaced in the same position when installing engine.
^ Additional removal information for vehicles with air conditioning.
- With ignition switched off disconnect battery Ground strap.
- Remove insulation tray:
- Remove front bumper.
- Drain coolant.
- Unbolt power steering hydraulic oil cooling line (arrows) and ensure it is free. Do not open hydraulic oil circuit.
- Remove lock carrier with attachments. Removal and Replacement
- Remove connecting pipes between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/throttle valve control module.
Vehicles with secondary air system
- Remove connecting pipes between secondary air pump/combination valve and secondary air pump/air cleaner.
Continued for all vehicles
- Remove ribbed belt, Refer to Drive Belts, Mounts, Brackets and Accessories.
- Unbolt power steering pump at compact bracket and place to side; hoses remain connected, Refer to Steering and Suspension.
Vehicles with air conditioner
- See additional information and removal instructions.
Continued for all vehicles
- Remove starter, Refer to Starting and Charging.
- Disconnect front exhaust pipe from catalyst, Refer to Exhaust Systems.
- Remove front catalyst from turbocharger, Refer to Exhaust Systems.
Vehicles without E-Gas System
- Disconnect throttle cable at throttle valve control module cable disc and support bracket (arrows). Do not remove locating clip on support bracket.
Continued for all vehicles
- Remove air cleaner.
- 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 all coolant hoses from engine.
- Remove connecting, vacuum and intake hoses from engine and turbocharger.
- 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 upper engine/transmission securing bolts.
- Remove lower right and left engine mounting securing nuts.
Vehicles with automatic transmission
- Separate torque convertor from drive plate (3 securing nuts).
Note: Secure torque converter so that it does not fall out after removing engine.
- Lift engine and transmission slightly with support T10062 and engine/transmission bracket VAG 1383 A to be able to remove lower engine/transmission connecting bolts
Continued for all vehicles
- Remove lower engine/transmission connecting bolts.
- Install engine support bracket 10222A with additional hooks 10222A/2 as follows:
- 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 VAG 1202 A
Pulley end: 4th hole in hook at position 1
Flywheel end: 3rd hole in hook at position 8
WARNING: The hooks and locating pins must be secured with locking pins (arrows).
Note:
^ The positions marked 1 to 4 on the bar must be toward the pulley end.
^ The holes in the hook rails are counted up from the hook.
- Lift engine out forward.
Note:
^ Guide the engine carefully when lifting out, to prevent damage to the bodywork.
^ When working on the engine, it should be secured to the engine stand using the engine bracket VW 540.
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 centering engine/transmission are in cylinder block, install if necessary.
- Replace engine mounting self-locking nuts.
- Align engine mountings stress-free by rocking.
- Install air conditioner compressor, Refer to Heating and Air Conditioning.
- Install power steering pump, Refer Steering and Suspension.
- Install ribbed belt, Refer to Drive Belts, Mounts, Brackets and Accessories.
- Install catalyst.
- Install front exhaust pipe to catalyst, Refer to Exhaust Systems.
- Install connecting lines between turbocharger/charge air cooler, turbocharger/air cleaner and charge air cooler/throttle valve control part.
- Install lock carrier with attachments: Removal and Replacement
Vehicles without E-Gas System
- Adjust accelerator cable, Refer to Powertrain Management.
Continued for all vehicles
- Electrical connections and routing.
^ Electrical Wiring Diagrams, Troubleshooting & Component Locations
- Remove starter.
- Install air cleaner.
- Fill with coolant, Refer to Cooling Systems.
- Check headlight alignment and adjust if necessary:
- Perform work sequence "Procedure after voltage supply open circuit".
- Carry out a test drive and interrogate Diagnostic Trouble Code (DTC) memory.
Tightening torques
M6 10 Nm
M8 20 Nm
M10 45 Nm
M12 60 Nm
exceptions:
Catalyst to turbocharger 30 Nm
Front exhaust pipe to catalyst 25 Nm
Starter to transmission 65 Nm
Front engine mounting
1. Cross tube
^ With torque reaction mounting
2. Bump stop
3. 30 Nm
4. 25 Nm
5. Connecting - piece
6. 45 Nm
7. Mount
8. Connecting - piece
9. 45 Nm
10. 25 Nm
11. Stop
^ Allow to move onto stop buffer under its own weight and tighten securing bolts
12. 30 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 the condenser and 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 ribbed belt.
- Remove air conditioner compressor:
- Secure air conditioner compressor to body so that refrigerant hoses/lines are not stressed.