Removing and Installing
Engine, removing and installing
Special tool and equipment
^ VW 313 Support clamp
^ VW 540 Engine and transmission support
^ 2024 A Lifting tackle
^ 3180 Retainer (for turbocharged engines)
^ V.A.G 1202 A Workshop crane
^ V.A.G 1306 Drip tray
^ V.A.G 1331 Torque wrench (5 to 50 Nm)
^ V.A.G 1332 Torque wrench (40 to 200 Nm)
^ V.A.G 1383A Engine/transmission jack
^ T10012 Engine bracket
^ VAS 5024 Assembly tool for spring-type clamps
^ VAS 5085 Step ladder (not shown)
^ G 000 100 Grease (vehicles with manual transmission) (not shown)
^ Bolt M10X25/8.8 (not shown)
^ Cable tie (not shown)
Removal notes
- Check whether a coded radio is installed. If so, obtain the anti-theft coding.
- The engine is removed downwards together with the transmission.
- With ignition switched off disconnect battery Ground strap.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
- Remove engine cover.
- Remove connecting hoses-arrows-between secondary air pump/combi-valve and secondary air pump/air cleaner.
Note: Press buttons on hose couplings to remove connecting hoses.
- Pull connector-1-off secondary air pump.
- Remove air cleaner.
- Pull vacuum and breather hoses off engine.
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.
- Pull off supply line/hose-1-(with white marking) and return line/hose-2-(with blue marking) and collect fuel that leaks out with a cloth.
- Pull hose off solenoid valve.
Note: Press buttons on hose couplings to do this.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Remove intake hose between air mass meter (G70) and turbocharger.
- Release intake hose (between charge air cooler and throttle valve control part) on throttle valve control part and pull off.
Vehicles with manual transmission
- Disconnect selector mechanism from transmission.
- Remove hydraulic clutch slave cylinder.
Note: Clutch pedal must not be depressed.
Vehicles with automatic transmission 01 M
- Remove selector lever cable from transmission.
Continued for all vehicles
- Remove insulation tray.
- Drain coolant.
- Disconnect coolant hoses from radiator at engine.
Note: The VAS 5024 assembly too/ or V.A.G 1921 pliers are recommended for installing the spring-type clamps.
- Remove pendulum support-arrows-.
- Disconnect all electric wires from transmission, generator and starter and move clear.
- Remove front exhaust pipe.
- Remove ribbed belt.
- Remove securing clamps for power steering pressure line.
- Remove power steering pump with bracket and set to one side: hoses remain connected.
- Pull off/disconnect all other electrical connections as necessary from engine and move to side.
- Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission.
Vehicles with air conditioner
- Removing air conditioner compressor.
- Observe additional notes and assembly work
Continued for all vehicles
- Install engine bracket T 10012 onto cylinder block with a securing nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm.
- Lift engine and transmission slightly using engine/transmission jack V.A.G 1383 A.
- Unbolt engine side of assembly mount from engine carrier at top-arrows-.
Note: To remove securing bolts use ladder VAS 5085 or equivalent..
- Unbolt transmission side of assembly mount from transmission carrier at top-arrows-.
- Carefully lower engine with transmission.
Note: Engine with transmission must be guided carefully when lowering to prevent damage to the bodywork.
Engine, securing to assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW 313 using the engine and transmission box support VW 540.
Work sequence
- Remove transmission.
Vehicles with automatic transmission
- Secure torque converter against "falling out" after separating engine from transmission.
Continued for all vehicles
- Attach lifting tackle 2024A with bracket 3180 as follows and lift off engine/gearbox jack V.A.G 1202A with workshop crane V.A.G 1383 A.
Pulley end: 3rd hole in hook at position 1
Flywheel end: 2nd hole in hook at position 5
WARNING! The hooks and locating pins must be secured with locking pins.
Notes:
^ The positions marked 1 through 4 on the bar must be towards the pulley end.
^ The holes in the hook rails are counted up from the hook.
- Secure engine to support clamp VW 313 using engine and transmission bracket VW 540.
Installation notes
Installation is carried out in the reverse sequence. Also note the following:
WARNING!
When doing any repair work, especially in the engine compartment, due to the cramped conditions, pay attention to the following:
^ Route all sorts of lines (e.g. for fuel, hydraulics, coolant, refrigerant, brake fluid and vacuum lines and hoses, etc.) and electrical wiring so that the original positions are restored.
^ Make sure sufficient clearance to all moving or hot components.
- Check whether the dowel sleeves for centering engine/transmission are in the cylinder block, install if necessary.
- Install intermediate plate onto sealing flange and slide onto dowel sleeves-arrows-
Vehicles with manual transmission
- Check centering of clutch drive plate, if necessary.
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft.
- Install hydraulic clutch slave cylinder.
- Install gear selector mechanism.
- If necessary adjust selector cables.
Vehicles with automatic transmission 01M
- Only use nuts approved in parts program to secure torque converter to drive plate.
- Install selector cable on transmission, adjust if necessary.
- Adapt control module for automatic transmission.
Continued for all vehicles
- When installing the assembly, make sure sufficient clearance to drive axles.
- Align engine and transmission mounts.
- Install drive shafts.
- Install front exhaust pipe, Removing and installing parts of exhaust system.
- Install intake hose (between charge air cooler and throttle valve control part) onto throttle valve control part and secure.
- Install ribbed belt.
- Install connecting hoses between secondary air pump to combination valve and secondary air pump to air cleaner.
- Install center, left and right insulation trays.
- Fill engine with coolant
Tightening torques
