Engine, Removing, General Information
Engine, Removing
Special Tools and Workshop Equipment Required:
- Holding fixture -VW 313-
- Engine and Transmission Holder -VW 540-
- Adapter Set for Engine and Transmission Support -VW 540/1B-
- Engine Support Bridge -10-222A- with Bracket for Engine -10-222 A1-.
- Lifting Tackle -2024A-
- Engine Support Adapter -3147- (vehicles with front wheel drive).
- Support -T10062-
- Drip Tray -V.A.G 1306-
- Torque Wrench -V.A.G 1331-
- Torque Wrench -V.A.G 1332-
- Engine/Transmission Jack -V.A.G 1383 A-
- Spring-type clip pliers -VAS 5034-
- Transmission Support -VW 785/1B- (vehicles with all wheel drive)
- Hose Clamps -VAS 3094-
- Grease -G 000 100- (vehicles with manual transmission)
- Cable tie
Torque Specifications:
Removing
- Engine is removed toward the front without transmission.
CAUTION!!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
- Ensure sufficient clearance to all moving or hot components.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
- Check if a coded radio is installed. Obtain the anti-theft code if necessary.
- Turn off the ignition and all electrical consumers.
- Disconnect batter ground (GND) strap.
- Remove lock carrier with attachements. Refer to: Service and Repair
- Remove intake manifold cover.
- Removed ribbed belt. Refer to: Service and Repair
- Remove generator. Refer to: Service and Repair
Vehicles with A/C
- Observe additional information and removal work, Refer to: Vehicles With A/C, Additional Removal Information
- Remove the air filter upper section with mass air flow sensor, connecting hose and intake air scoop. Refer to: Service and Repair
- Drain the coolant. Refer to: Service and Repair
- Remove the coolant reservoir and move it to the side.
Vehicles with Accelerator Pedal Cable
- Remove vacuum diaphragm for Cruise Control System -CCS- (only vehicles with CCS).
- Disengage the accelerator pedal cable at the cable pulley of throttle valve control module and at the cable mounting bracket -arrows-. Do not remove the positioning clip on the cable mounting bracket.
- Observe the rules for cleanliness.
WARNING!!!
Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Separate the fuel supply line -2- (counterhold at hex of fuel rail) and the fuel return line -1- at the fuel rail.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Disconnect pressure hose for power steering system from connection point -3- and disconnect line from rear coolant pipe.
NOTE:
Catch escaping oil
- Clamp off intake hose to power steering pump before connection engine using -VAS 3094- and disconnect hose from pipe on cylinder head, bank 2 (left) at front.
- Clamp off connection-, coolant-, vacuum- and intake hoses from engine.
- Pull off/disconnect all electrical wires from engine and set aside.
- Remove the right and left heat shield/driveshaft -arrows-. Third bolt is not visible in the illustration.
- Remove the left and right front exhaust pipe from the exhaust manifold. Please refer to: Service and Repair
- Remove starter. Refer to: Service and Repair
With AWD
- Secure driveshaft with -3213- and unfasten the intermediate bearing from vehicle floor.
NOTE:
During this work procedure, the driveshaft must not be separated from the transmission.
For Manual Transmission, refer to: Service and Repair
For Automatic Transmission, refer to: Service and Repair
Vehicles with Automatic Transmission:
- Separate the torque converter from the drive plate (3 nuts), refer to: Service and Repair
- Remove connecting bolts for engine/transmission.
- Remove attaching nuts for right and left motor mounts.
- Unfasten torque support from oil pan and secure -T10062-
- Raise engine using -V.A.G 1383 A- and -T10062- in order to be able to remove the lower transmission bolts.
- Remove lower engine/transmission connecting bolts and lower subframe again.
With FWD
- Install -10-222A- as shown.
- Hook in -3147- into bolt holes of transmission bell housing (shown illustration with engine removed).
With AWD
- Support transmission at subframe -arrows- using -VW 785/1B- and wood block (approximately 40 x 120 x 200 mm for automatic transmission, positioned longitudinally).
NOTE:
- Transmission support chain must be hooked in as short as possible.
- Illustration shows the support of the automatic transmission. Adapt wood block accordingly to support manual transmission.'
- Loosen bolts -1- for transmission mount 3 turns.
CAUTION!!!
Use securing pins at hooks and pins -arrows-.
- Hook in -2024 A- as follows and raise slightly using -1202 A-:
- Belt pulley side:
2. Hole of rail in position 2
4. Hole of rail in position 8
NOTE:
- The peg positions on the carrying strap marked 1 to 4 face the belt pulley.
- The bores in the hole rail are counted from the hook.
- Remove engine toward front.
NOTE:
Engine must be guided carefully when lifting out, to prevent damage to the body.
Vehicles with Automatic Transmission
- Secure the torque converter to prevent it from "falling out" after the engine is removed.