Engine, Removing
Engine, removing
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to the confined conditions:
^ Route all the various lines (e.g. for fuel, hydraulic system, EVAP system, coolant, refrigerant, brake liquid, vacuum) and electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.
The engine is removed in a downward direction together with the transmission.
Note:
^ All cable ties which are opened or cut through when the 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 radio anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Remove air cleaner.
- Remove intake hose between Mass Air Flow (MAF) sensor -G70- and turbocharger.
- Remove power steering reservoir from battery carrier but do not disconnect/open hoses.
- Place reservoir on lock carrier.
- Remove battery and battery bracket.
- Pull vacuum and breather hoses off engine.
CAUTION!
Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Disconnect supply hose - 3 - and return hose - 2 - and collect fuel that leaks out with a cloth.
- Pull hose off EVAP canister purge regulator valve -N80-
Note:
^ Press locking ring inward to release fuel lines.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Loosen hose clip - 2 - from intake hose (between charge air cooler and throttle valve control module) on throttle valve control module and pull hose off.
- Disconnect connectors for Intake Air Temperature (IAT) sensor -G42- (if part of equipment) - 1 - and Throttle valve control module -J338- - 4 - below throttle valve control module.
- Disconnect connector from Camshaft Position (CMP) sensor -G40- - arrow -.
- Remove bolts from vacuum reservoir on cylinder head cover and pull it off bracket.
- Pull injector connectors off and unclip fuel rail bracket.
- Take off Ground cable between ignition coils 1 and 2.
- Disconnect injector connectors.
- Disconnect connector from Speedometer vehicle speed sensor -G22- (rear).
- Remove center, left and right side sound insulation.
- Remove air duct pipe to charge air cooler on longitudinal member lower right - arrows -.
Vehicles with 5 speed manual transmission 02J
- Disconnect selector mechanism from transmission.
- Remove hydraulic clutch slave cylinder.
Note:
^ The clutch pedal must not be depressed.
Vehicles with 5 & 6 speed manual transmission 02M
- Disconnect selector mechanism from transmission.
- Remove hydraulic clutch slave cylinder.
Note:
^ The clutch pedal must not be depressed.
Vehicles with automatic transmission 01M
- Disconnect selector lever cable from transmission.
Vehicles with automatic transmission 09G
- Disconnect selector lever cable from transmission.
Continuation for all models
- Drain coolant.
- Pull engine coolant hoses off with spring-type hose clip pliers VAS 5024 A.
- Disconnect coolant hoses on heat exchanger.
- Pull off coolant hose to throttle valve control module coolant pipe.
- Remove supplementary coolant fan on right side of vehicle, if part of original equipment.
- Disconnect both coolant fan connections on lower left radiator frame.
- Disconnect all other interconnecting, coolant, vacuum and intake hoses from engine.
- Remove bolts from secondary air injection pump motor and bracket and remove.
- Disconnect all electrical wiring from transmission, Generator and Starter and move clear.
- Disconnect all other electrical connections as necessary from engine and move wiring to one side.
- Remove securing clamps for power steering pressure line.
- Remove ribbed belt.
- Remove power steering pump from bracket and tie up to front panel; hoses remain connected.
Vehicles with air conditioning
- Remove air conditioning compressor.
- Note additional information and removal work on models with air conditioning.
Continuation for all models
- Remove protective shield for inner right constant velocity joint from engine.
- Remove right side axle shaft and disconnect left side axle shaft at transmission.
- Remove pendulum support - arrows -.
- Remove front exhaust pipe with catalytic converter.
- Remove oil pan protection if part of original equipment
- Secure engine and transmission support T10012 to cylinder block with securing nuts and bolt M1025/8.8. Tighten to approx. 40 Nm.
- Lift engine and transmission slightly using engine/transmission jack V.A.G 1383 A.
- Remove bolts for engine side of assembly mounting from engine bracket at top - arrows -.
Note:
^ To remove securing bolts use step ladder VAS 5085 or an equivalent.
- Remove bolts from transmission side of assembly mounting from transmission bracket at top - arrows -. Carefully lower engine with transmission.
- While lowering, guide power steering pressure line past transmission.
Note:
^ The engine and transmission must be guided carefully when lowering to prevent damage to the bodywork.