Engine, Removing And Installing

Engine, removing and installing





Special tools and equipment
^ 2024A Engine sling
^ T10012 Engine/trans support
^ VW313 Holding fixture
^ VW540 Holding fixture engine / transmission support
^ VAG1202A Workshop crane
^ VAG1306 Drip tray for VAG1202A





Special tools and equipment
^ VAG1331 Torque wrench: 5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG1332 Torque wrench: 40 to 200 Nm (30 to 148 ft. lbs.)
^ VAG1383A engine/transmission jack
^ VAG1921 Hose clip pliers
^ VAS5085 Step ladder
^ G 000 100 grease (manual transmission only)
^ M10X25/88Bolt
^ Cable tie

CAUTION: Obtain the radio anti-theft code from the customer BEFORE disconnecting the battery Ground strap.

Note:
^ After making sure that the ignition is switched OFF, disconnect the battery Ground strap.
^ All cable ties which were opened or cut open to remove the engine/transmission assembly, must be replaced in the original position when installing the engine.
^ Remove the engine/transmission assembly downward.
^ Remove the engine cover.
^ Remove power steering reservoir from battery support, thereby not having to loosen the fluid hoses.
^ Attach coolant reservoir to upper radiator support.
^ Remove the battery and battery hold-down.
^ Remove Air Cleaner.
^ Remove connecting pipe between the Charge Air cooler and intake manifold complete with EGR Vacuum Regulator solenoid valve -N18-.





- Disconnect fuel supply and return lines at fuel filter.
- Seal off lines so fuel system is not contaminated by dirt etc.

Vehicles with manual transmission
- Disconnect selector mechanism from transmission.
Vehicles with automatic transmission
- Remove Transmission Range selector lever cable from transmission:





All vehicles
- Remove sound dampening tray:
- Drain engine coolant
- Remove line between charge air cooler and turbocharger.
- Pull radiator hoses off engine using VAG1921 hose clip pliers.
- Remove lower coolant hose from radiator.
- Remove auxiliary filter, if available, on right side of vehicle.





- Loosely unscrew pendulum support (arrows).
- Pull vacuum and breather hoses off engine.
- Disconnect all wiring from the transmission, Generator and starter and move them to one side for clearance.
- Remove front exhaust pipe
- Remove ribbed belt.
- Remove power steering pump with bracket and lay to one side.
^ Hoses remain connected:
- Remove right hand inner Constant Velocity joint protective cover from engine if installed.
- Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission:
- Unscrew mounting bolts for power steering pressure line.

Vehicles with A/C:
- Observe additional information and removal instructions.
- Remove starter.

All vehicles:
- Insert engine bracket 3396 into VAG1383A engine / transmission jack.
- Remove coolant hose bracket and lower from cylinder block.
^ Thread hole is used to fasten T 10012 engine bracket





- Thread on T 10012 engine bracket using M10x 25 5/8.8 nut and bolt.
^ Attach to engine block with 25 Nm (18 ft. lbs.)
- Slightly lift engine/transmission assembly using VAG1383A jack.





- Loosely unscrew engine mount (engine side) from top of engine bracket (arrows).

Note: Use VAS5085 tool to remove the mounting bolts.





- Loosely unscrew engine mount/transmission mount from transmission bracket (arrows) from top.
- Carefully lower engine/transmission assembly.
- While lowering, carefully guide the power steering fluid line past the transmission.

Note: Carefully guide the engine and transmission assembly during the lowering process to prevent bodywork damage.