Notes on Removing
Notes on removing
CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
^ Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses) and electrical wiring so that the original positions are restored.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.
^ Ensure sufficient clearance to all moving or hot components.
Note: Engine is removed toward the front without transmission.
- First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.
- Switch off ignition and all electrical consumers.
- Disconnect battery Ground (GND) strap.
- Remove noise insulation.
- Remove front bumper
- Drain coolant.
- Unbolt engine coolant expansion tank and lay aside.
- Unbolt cooling coil for power steering fluid (arrows) and let hang free; Do not open hydraulic fluid circuit.
Vehicles with automatic transmission:
- Disconnect ATF lines at connections - arrows - and catch escaping ATF.
Vehicles with air conditioning:
- Observe additional notes and repair work.
Continued for all vehicles:
- Remove lock carrier with attachments. Removal and Replacement
- Remove air pipe between intercooler and throttle valve.
- Remove ribbed belt.
- Unbolt power steering pump at bracket and lay to one side, hoses remain attached.
- Remove air filter housing.
- Remove catalytic converter.
- Remove starter.
- Observe the rules for cleanliness.
CAUTION! Fuel supply line is under pressure! Wear eye protection and protective clothing in order to avoid injuries by contact with fuel. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.
- Disconnect fuel supply and fuel return lines at fuel distributor.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Separate the pressure hose of the Secondary Air Injection (AIR) Pump at the connecting tube.
- Remove crankcase ventilation tube - 1 -.
- Disconnect pressure tube - 2 - at combination valve - arrow - and unbolt from cylinder head cover.
- Unbolt combination valve with mount - 3 - and set aside.
- The vacuum hose remains attached.
- Disconnect connector - 4 - from coolant temperature sensor.
- Remove crankcase ventilation T-piece - 5 -.
- Remove the coolant hoses between the heater core and expansion tank.
- Disconnect electrical connectors and vacuum hoses from the engine as necessary.
- Remove Engine Control Module (ECM).
- Disconnect engine wiring harness from central unit and lay aside.
- Pull off/disconnect all electrical connections as necessary from engine and lay aside.
- Remove connecting bolts for engine/transmission.
Note: Loosen, but do not remove one of the connecting bolts.
- Remove attaching nuts for right and left motor mounts.
Vehicles with automatic transmission
- Disconnect torque converter from drive plate (3 securing bolts).
Note: After removing engine, secure the torque converter to prevent it from falling out.
- Unbolt stop - 1 - - arrows -.
- Secure changed mount T10062 in center hole at right side of oil pan.
- To do this, tighten original bolt with 3 original washers (each 4 mm thick) - arrow - to 30 Nm.
- Using support T10062 and engine/transmission jack V.A.G 1383 A, raise engine and transmission until the lower connecting bolts for engine/transmission can be removed.
Note:
^ When lifting engine, make sure that the crankcase housing ventilation tube does not touch the bulkhead and that no lines are pinched.
^ To do so, use the step ladder VAS 5085.
Continued for all vehicles
- Remove lower connecting bolts for engine/transmission.
- Attach engine support bridge 10-222 A with additional hooks 10-222 A/2 as shown.
- Hook in engine support adapter 3147 into bolt holes of transmission bell housing (shown in illustration with engine removed).
- Hook in engine sling 2024 A using strap T10059 as follows and raise slightly using workshop crane 1202 A :
- Belt pulley side: 2. Hole of rail in position 1
- Dual-mass flywheel side: 1. Hole of rail in position 8
CAUTION! Use securing pins at hooks and pins, to prevent damages to engine and vehicle.
Note:
^ The peg positions on the carrying strap marked with 1 to 4 face the belt pulley.
^ The bores in the hole rail are counted from the hook.
- Lift up engine with transmission far enough until the threaded pins of engine mounts clear the mounts.
- Lift up transmission at the same time using spindle of engine support bridge 10-222A.
Note: When lifting engine, make sure that the crankcase housing ventilation tube does not touch the bulkhead and that no lines are pinched.
- Remove upper engine/transmission bolt.
- Remove engine toward front.
Note: Engine must be guided carefully when lifting out, to prevent damage to the body.
Secure engine to assembly stand using holding fixture VW 540 and adapter set VW 540/1B when performing repair work.