Engine/Transmission, Removal Notes
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.
- Make sure ignition is switched OFF then disconnect battery Ground strap
- Remove engine cover.
Note: All cable ties which are opened or cut open to remove the engine, must be replaced in the same position when re-installing the engine.
- Remove power steering fluid reservoir from battery support but do not disconnect hoses.
- Tie reservoir to lock support
- Remove battery and battery bracket
- Pull off or disconnect all other electrical connections as necessary from engine and body and lay to one side.
- Remove Air Cleaner
- Pull vacuum and breather hoses off engine.
WARNING:
^ Fire Hazard! Do NOT have anything in the area that can ignite fuel!
^ 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.
- Observe rules of cleanliness:
- Pull off fuel supply line -1- (with white mark) and return hose -2- (with blue mark) and collect fuel that leaks out 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.
Vehicles with manual transmission
- Disconnect transmission range selector mechanism from transmission.
- Disconnect all electric wires from transmission, Generator and starter and move to one side.
- Remove hydraulic clutch slave cylinder
Note: Clutch pedal must not be depressed.
Vehicles with automatic transmission
- Remove Range selector lever cable from transmission:
Continued for all vehicles
- Remove intake manifold upper section
- Remove Secondary Air Injection pump motor -V101- and bracket
- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Pull off/disconnect all other electrical connections from engine and lay to one side if necessary.
- Remove ribbed belt.
- Remove sound dampener tray:
- Drain coolant.
- Pull radiator coolant hoses off engine using pliers VAG1921 orVAS5024.
- Remove coolant hoses at heather core.
- Remove coolant hose to coolant pipe at throttle valve control unit.
- Remove auxiliary fan on right side of vehicle, if applicable.
- Disconnect both harness connectors for cooling fan at notch at left bottom.
- Unscrew mounting clamps for power steering pressure lines
- Remove power steering pump with bracket and lay to one side; hoses remain connected.
- Remove right hand inner Constant Velocity (CV) joint protective cover from engine if installed.
- Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission:
- Remove pendulum support bolts -arrows-.
- Remove front exhaust pipe with catalytic converter
- Remove bracket for coolant hose under engine block.
- Mount engine bracket T10012 using threaded hole.
- Install engine bracket T10012 in VAG1383 A engine/transmission jack.
- Install engine bracket T 10012 onto cylinder block with a securing nut and M10 X 25/8.8 bolt.
^ Tightening torque: 40 Nm (30 ft. lbs.)
- Carefully lift engine and transmission using VAG1383 A engine/transmission jack.
- Unscrew engine side of assembly mount bolts -arrows- from the top (from the engine mount).
Note: Stand on VA S5085 ladder or equivalent to reach mounting bolts.
- Remove bolts (transmission side) from transmission mount -arrows- from the top.
- Carefully lower engine with transmission assembly.
- Guide power steering pressure line past transmission when removing engine/transmission assembly.
Note: Engine with transmission must be guided carefully when lowering to prevent damage to the bodywork.