Engine, Removing

Engine, removing

Work sequence
The engine is removed downward together with the transmission.

Caution: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
^ Ensure that there is sufficient clearance to all moving or hot components.

Note:
- All cable ties which are opened or cut through when engine is removed must be replaced in the same position when the engine is installed.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery ground strap.
- Remove engine cover.
- Remove battery and battery retainer.
- Remove air cleaner.
- Disconnect pipe between charge air cooler and intake connecting flange at intake connecting flange.
- Disconnect fuel supply and return lines at fuel filter.

Caution:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release the pressure!
^ Wear eye and hand protection when performing any type of repair work on the fuel system!

Vehicles with manual transmission 02J
- Remove hydraulic clutch slave cylinder

Vehicles with automatic transmission
- Remove selector lever cable from transmission:

Continuation for all vehicles
- Remove center, left and right sound insulation trays:
- Drain coolant.
- Disconnect connector from thermal switch and coolant fan.
- Pull coolant hoses off radiator.
- Disconnect all electrical wiring from transmission, Generator and starter and move clear.





- Unbolt pendulum support in order shown - arrows -.
- Remove front exhaust pipe.

- Remove poly V-belt.
- Unbolt power steering pump from bracket and move aside. Hoses remain connected:
- Separate all connections from engine for coolant, vacuum and intake hoses.
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
- Remove right side axle shaft and disconnect left side axle shaft at transmission:
- Remove securing clamps for power steering pressure line.

Vehicles with air conditioning
- Observe additional information and removal work.





Continuation for all vehicles

- Insert engine bracket T1 0012 in engine/transmission jack V.A.G1383A.

- Fit engine bracket T1 0012 onto cylinder block with a securing nut and M1 Ox25/ 8.8 bolt and tighten to approximately 40 Nm.

- Lift engine and transmission lightly using engine/transmission jack V.A.G1 383A.





- Unbolt engine side of assembly mounting from engine carrier at top - arrows -

Note: To remove securing bolts use step ladder VAS 5085.





- Unbolt transmission side of assembly mounting from transmission carrier at top - arrows - .
- Carefully lower engine with transmission.

Note: The engine and transmission must be guided carefully when lowering to prevent damage to the bodywork.