Engine, Removing
Engine, removing
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 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 anti-theft coding.
- With ignition switched off disconnect battery Ground strap.
- Remove engine cover.
- Remove power steering reservoir from battery mounting; do not disconnect hoses.
- Fasten reservoir to lock carrier.
- Remove battery and battery retainer.
CAUTION!
The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
Engine codes AEG, AVH, AZG, BDC
- Pull fuel supply line - 1 - and fuel return line - 2 - off fuel rail.
Engine codes BEV, BGD
- Disconnect fuel supply line at connection - 1 - by sliding securing ring - 2 - in union connection - 3 -.
Continued for all engine codes
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove air cleaner.
- Remove intake manifold upper part.
Note:
^ Seal the intake ports in the intake manifold lower part with a clean cloth.
Vehicles with manual transmission
- Disconnect selector mechanism from transmission.
- Remove hydraulic clutch slave cylinder.
Note:
^ The clutch pedal must not be depressed.
Vehicles with 4 Spd. Automatic Transmission 01M
- Remove gate selector cable from transmission.
Vehicles with 6 Spd. Automatic Transmission 09G
- Remove gate selector cable from transmission.
Continued for all models
- Remove middle as well as left and right side sound insulation.
- Drain coolant.
- Remove poly V-belt.
- Remove auxiliary fan on right side of vehicle, if part of equipment.
- Remove securing clamps for power steering pressure line from engine and transmission.
- Remove power steering pump at bracket and fasten to front end; hoses remain connected.
Vehicles with air conditioning
- Remove air conditioning compressor.
- Note additional information and removal work on models with air conditioning.
Continued for all models
- Disconnect air intake hose, coolant and vacuum hoses from engine.
- Remove bracket with secondary air pump motor.
- Disconnect all electrical wiring from transmission, Generator and starter and move wiring clear.
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
- Disconnect pendulum support - arrows -.
- If part of equipment, remove protective cap from engine for inner right constant velocity joint.
- Remove right side axle shaft and disconnect left side axle shaft at transmission.
- Remove front exhaust pipe with catalytic converter Exhaust manifold / front exhaust pipe with catalytic converter and attachments, assembly overview.
- If part of equipment, remove oil pan guard.
- Insert engine/transmission support T10012 in engine/transmission jack V.A.G1383A.
- Remove retainer of lower coolant hose from cylinder block. Threaded bore is necessary for fastening engine/transmission support T10012.
- Fit engine/transmission T10012 onto front of cylinder block with an M1 0x25 / 8.8 bolt and tighten to approx. 40 Nm.
- Tighten nut on exhaust side by hand.
- Lift engine and transmission lightly using engine/transmission jack V.A.G1383A.
- Unbolt engine mounting from engine carrier at top - arrows -.
Note:
^ To remove securing bolts use step ladder VAS5085 or equivalent.
- Remove bolts - arrows - of mounting from transmission bracket at top - arrows-.
- Carefully lower engine with transmission.
- While lowering, guide power steering pressure line past transmission.
Note:
^ The engine, together with the transmission, must be guided carefully when lowering to prevent damage to the bodywork, hoses and other lines.