Engine, Removing

Engine, Removing

Special tools, testers and auxiliary items required

• Lifting tackle (2024 A)

• Engine mount (T10012)

• Holding fixture (VW 313)

• Engine and transmission holder (VW 540)

• workshop crane (VAS 6100) or

• Shop crane (V.A.G 1202 A)

• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

• Engine/transmission jack (V.A.G 1383 A)

• Spring-type clip pliers (VAS 5024A)

• Step ladder (VAS 5085)

• Cable tie

• To perform work sequence, the ground cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti theft coding beforehand.

• The engine is removed downward together with the transmission.

• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

Procedure

- Remove battery

- Remove battery holder bolts - arrows - and holder.





- Remove plenum chamber bulkhead

- Remove radiator => [ Radiator ] Service and Repair.

With Manual Transmission

- Remove the hydraulic clutch slave cylinder.

- Remove the shift mechanism from the transmission.

With DSG

When touching metal parts, it is possible that an electrostatic discharge could occur. The reason for this is the electrostatic charge of the human body. This charge can lead to functional problems by touching the electrical components of the transmission and selector lever mechanism.

- Touch a grounded object, e.g. a water pipe or a lifting platform, before working on the Mechatronic unit.





- Do not make direct contact with the connector terminals.

- Turn the bayonet connection - 1 - of the connector toward the left and pull the connector off from transmission.





- Remove the selector lever cable on the transmission.

- Disconnect the connector - arrow 1 -.





- Disconnect the vacuum hoses - arrow 2 -.

- Disconnect vacuum hose - arrow 3 - at check valve for brake booster.

Continuation for All

- Disconnect vacuum hose - arrow - to brake booster at tandem pump.





- Disconnect coolant hoses - arrows - to heater core at the bulkhead.





- Unscrew ground (GND) wire nut - 1 -.





- Disconnect wires - 2 - and - 3 - on starter.

- Free up the cables.

- Disconnect connector - arrow - at Engine Coolant Temperature (ECT) sensor (G62).





- Pull the release pin - arrow 1 - and open the knurled nut - arrow 2 -.





- Pull off the central connector for pump injector unit and free up the wiring harness.

- Disconnect connector - arrow - at fuel temperature sensor (G81) and free up the wiring.





CAUTION!
• The fuel or fuel lines in fuel system can become very hot (danger of scalding)!

• In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!

• Wear protective goggles and protective gloves when working on the fuel system!

- Mark the hoses - 2 -, remove them and free them up.





- Remove the connecting hoses and the connecting pipe. To do this, slightly lift the retaining clips - 1 - and remove the bolts - 3 - from the lifting eye.

- Disconnect the fuel supply line - 3 - and the fuel return line - 2 -. To do this, pull the release buttons.





- Disconnect the coolant hose - 1 - from the coolant expansion tank.

- Only slightly loosen bolts - arrows - of engine mount at engine mount bracket (less than 1 rotation).





- Only slightly loosen bolts - arrows - of transmission mount at transmission (less than 1 rotation).





- Disconnect connector - arrow - at intake flap motor (V157).





- Remove connector - arrow - for Camshaft Position (CMP) sensor (G40) from the bracket and disconnect it.





- Disconnect the connector - arrow - at oil pressure switch (F1).





- Unscrew oil pressure switch.

- Disconnect the connector - arrow - at engine speed (RPM) sensor (G28) with assembly tool (T10118).





• To release the connector without the assembly tool (T10118), push the connector against the engine speed sensor and simultaneously lift up on the release tab with a thin wire hook.

- Remove nut - arrow - and remove wiring bracket from threaded stud.





- Free up cable.

- Disconnect the connector strip from the glow plugs - arrows -.





- Free up the wiring harnesses to the body.

With Air Conditioning

• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

CAUTION!
The air conditioning refrigerant circuit must not be opened.

- Remove screws - 2 - and - 3 - on the refrigerant line brackets.





To facilitate removal and installation of the engine without having to open the refrigerant circuit:

- Remove ribbed belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.

- Remove A/C compressor from the bracket.

- Secure A/C compressor to lock carrier so that the refrigerant lines/hoses are not burdened.

- Remove the generator.

- Remove right and left drive axles from the transmission.

- Remove the front exhaust pipe with the catalytic converter => [ Front Exhaust Pipe ] Service and Repair.

- Pull off/disconnect all electrical connections, as necessary, from engine and transmission and lay them aside.

- Disconnect all coolant, vacuum, and intake hose connections from engine.

- First unscrew bolt - 1 -.





- Unscrew bolts - 2 - and - 3 - and remove pendulum support.

- Set engine/transmission support (T10012) into engine/transmission jack (V.A.G 1383 A).





• The mounting pins must be secured to the engine support (T10012) as shown.

- Fasten the engine support (T10012) to cylinder block with bolt (M10 x 25/8.8) to approximately 40 Nm.

- Lift engine and transmission slightly using the engine/transmission jack (V.A.G 1383 A).

• Use step ladder (VAS 5085) to remove mounting bolts.

- From above, unbolt the engine mount - arrows - from the engine mount bracket on the engine side.





- From above, unbolt the transmission mount - arrows - from the transmission bracket on the transmission side.





• Verify that all hose and line connections between engine, transmission and body have been disconnected.

• While lowering, carefully guide engine/transmission assembly in order to prevent damages.

- Carefully lower the engine with transmission downward.