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 (GND) 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.
- Disconnect shift mechanism from transmission.

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 T10012 in engine/transmission jack V.A.G 1383 A.





- Install engine bracket T10012 onto cylinder block with a securing nut and M10x25/8.8 bolt and tighten to approx. 40 Nm.
- Lift engine and transmission lightly using engine/transmission jack V.A.G 1383 A.





- 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.