Removing and Installing

Special tools and equipment

^ 3147 Engine support adapter
^ 10-222A2 additional hook
^ 2024A Engine Sling
^ 10-222A engine support bridge with 10-222A-1 feet
^ VW313 holding fixture
^ VW540 holding fixture

^ VAG1306 drip tray
^ VAG1331 torque wrench (5 to 50 Nm)
^ VAG1332torque wrench (40 to 200 Nm)
^ VAG 1383A engine/transmission hoist
^ T10062 mount
^ VAS5024 assembly tool for spring-type clamps

^ VW540/1B auxiliary set for engine and transmission hoist
^ VAG 1202A Engine Hoist
^ VAS5085 ladder
^ T10059 strap
^ G 000 100 grease (vehicles with manual transmission)
^ Cable ties

Changing T10062 mount

- Drill an additional hole centered in height of the lower bore if not yet present.
a = 8.5 mm

Removal notes

Procedure
^ Determine whether a coded radio is installed. If so, determine the correct coding.

Note:
^ Engine is removed toward the front without transmission.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.

- Switch ignition off and disconnect battery Ground (GND) strap.
- Remove noise insulation. Service and Repair
- Remove front bumper: Service and Repair
- Remove front bumper: Service and Repair
- Drain coolant, Refer to Cooling System.

- Unbolt engine coolant expansion tank and lay aside.
- Unbolt cooling coil for power steering fluid (arrows) and let hang free; Do not open hydraulic fluid circuit.

Vehicles with automatic transmission

- Disconnect ATF lines at connections (arrows) and catch escaping ATF.

Vehicles with A/C system
- Observe additional notes and repair work, Refer to Additional Notes.

Continuation for all vehicles
- Remove lock carrier with attachments: Removal and Replacement
- Remove connecting tube from charge air cooler/throttle valve control module.
- Remove ribbed belt, Refer to Drive Belts, Mounts, Brackets and Accessories.
- Unbolt power steering pump at bracket and lay to one side, hoses remain attached: Refer to Steering and Suspension.
- Remove air filter housing: Refer to Powertrain Management.
- Remove catalytic converter: Refer to Powertrain Management.
To do so, remove mounts for front exhaust pipe at transmission.
- Remove starter: Refer to Starting and Charging.
- Disconnect fuel supply and fuel return lines at fuel distributor.

WARNING! Fuel supply line is under pressure! Before loosening hose connections, place rags around the connection point. Then release pressure by carefully pulling on hose

- Disconnect pressure hose for Secondary Air Injection (AIR) Pump at connecting tube.

- Remove tube for crankcase housing ventilation -1-.
- Disconnect pressure tube -2- at combination valve (arrow) and unbolt from cylinder head cover.
- Unbolt combination valve with mount -3- and lay to side.
Vacuum hose remains connected.
- Disconnect connector -4- from coolant temperature sensor.
- Remove T-piece -5- of crankcase housing ventilation.
- Disconnect coolant hoses to heater core and to reservoir at engine.
- Disconnect required connecting- and vacuum hoses from engine.
- Remove Engine Control Module (ECM), Refer to Powertrain Control Module.
- Disconnect engine wiring harness from central unit and move clear.
- Remove all remaining electrical wires from engine and set aside.
- Remove upper connecting bolts for engine/transmission.

Note: Loosen one connecting bolt, but do not remove.

- Remove bottom securing nuts for engine mount at right and left.

Vehicles with automatic transmission

- Disconnect torque converter from drive plate (3 securing bolts).

Note: after separating engine from transmission, secure the torque converter to prevent it from falling out.

- Unbolt stop -1- (arrows).

- Secure changed T10062 mount in center hole at right side of oil pan.
Tighten original bolt with 3 original washers (each 4 mm thick) -arrow- to 30 Nm.
- Lift up engine and transmission using T10062 mount and VAG1383 engine/transmission hoist far enough to be able to remove lower connecting bolts for engine/transmission.

Note: When lifting engine, make sure that the crankcase housing ventilation tube does not touch the bulkhead and that no lines are pinched.

To do so, use VAS5085 ladder.

Continuation for all vehicles
- Remove lower connecting bolts for engine/transmission.

- Set 10-222A engine support bridge with 10222A/2 additional hook in place as shown.
- Hook in 3147 engine support adapter into bolt holes of transmission bell housing (shown in illustration with engine removed).

- Hook in 2024A engine sling with T10059 strap as follows and slightly lift up using VAG1202 workshop crane.
Belt pulley side: 2. hole of rail in position 1
Flywheel side: 1. Hole of rail in position 8

WARNING! Use securing pins at hooks and pins (arrows).

Note:
^ The peg positions on the carrying strap marked with 1 through 4 face belt pulley.
^ Holes in the rails are counted from the hook.

- Lift up engine with transmission far enough until the threaded pins of engine mounts clear the mounts. Lift up transmission at the same time using spindle of 10-222A engine support bridge.

Note: When lifting make sure that the crankcase housing ventilation tube does not touch the bulkhead and that no lines are pinched.

- Remove upper connection bolt for engine/transmission.
- Lift out engine toward front.

Note: Engine must be guided carefully when lifting out to avoid damage to the body.

For repair work, secure engine to assembly stand using VW540 holding fixture together with VW540/1B auxiliary pieces.

Installation notes
Procedure
Installation is the reverse of removal. Note the following:

Vehicles with manual transmission
- Check clutch release bearing for wear and replace if necessary.
- Lubricate clutch release bearing and splines of input shaft with thin coating of G 000 100 (do not lubricate guide sleeve for release bearing).
- A pilot needle bearing must be installed in the crankshaft in engines for vehicles with manual transmission. Install needle bearing if necessary, Refer to Transmission and Drivetrain.

Vehicles with automatic transmission
- Use original bolts when securing torque converter to clutch disc.
see part supplier
- Before installing engine, turn torque converter and clutch disc such that a bore is level with the starter installation opening.

Continuation for all vehicles
- Make sure intermediate plate is correctly seated on engine.
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
- Replace self-locking nuts for securing engine mount.
- Align mounting of engine with shaking motions free of stress.
- Install A/C compressor: Refer to Heating and Air Conditioning.
- Install power steering pump: Refer to Steering and Suspension.
- Install ribbed belt, Refer to Drive Belts, Mounts, Brackets and Accessories.
- Install catalytic converter: Refer to Powertrain Management.
- Re-connect all lines, hoses and harness connectors that were disconnected during removal.
- For harness connectors and routing: Refer to Wiring Diagrams.
- Install starter:
- Install air filter housing:
- Install lock carrier with attachments. Removal and Replacement
- Top up coolant
- Check headlight adjustment, correct if necessary:

Vehicles with automatic transmission

- Connect ATF lines (arrows).
- Check ATF level, top up if necessary: Refer to Transmission and Drivetrain.
- Adapting kick-down shift point: Refer to Powertrain Management.

Continuation for all vehicles
- Perform work step "Procedure after interruption of voltage supply".
- Perform road test and check DTC memory:

Tightening torques