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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) and supplementary set (VW 540/1B)

• Shop crane (V.A.G 1202 A) or Shop crane (VAS 6100)

• Drip tray (V.A.G 1306) or ( VAS 6208)

• Torque wrench (V.A.G 1331)

• Torque wrench (V.A.G 1332)

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

• Pliers for spring clamps (VAS 5024) or (VAS 5024 A)

• Step ladder (VAS 5085)

• Grease (G 000 100)

• Screw M10 x 25/8.8

• M10 nut

• Cable tie

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.

• 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.

Procedure

- 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.

- With the ignition switched off disconnect battery Ground (GND) cable.

- Remove oil dipstick.

- Remove engine cover. First pull the front engine cover upward with a quick jerk - arrows A - and then pull it forward out of the rear mounting - arrow B -.





- If present, remove the insulation- arrow -.





- Remove the air filter housing and the intake hose.

- Remove the power steering reservoir from the battery tray; be sure not to loosen the hoses.

- Tie the reservoir to the lock carrier.

- Remove the battery and the battery tray.

- Disconnect the lower charge air pipe - 1 -. Remove the bolt - 2 - and release the electrical connections - arrows -. Carefully cover or seal any open ends.





- Remove the center, left and right noise insulation.





- Drain coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

- Disconnect the rear coolant hose from the oil cooler.

- Disconnect the radiator coolant hoses from the engine using hose clamp pliers (V.A.G 1921) or spring clamp pliers (VAS 5024 A).

- Remove the generator wiring harness and free it up.

- Disconnect all electrical wires from the transmission and the starter and free them up.

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 cloths around the connection area and release pressure by carefully loosening the connection!

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

- Disconnect the fuel supply hose - 1 - and the fuel return hose - 2 - from the fuel lines on the cylinder head.





- Seal the lines so that the fuel system is not contaminated by dirt etc.

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

With Manual Transmission

- Remove the shift mechanism from the transmission:

• => Manual Transmission 34 Manual Transmission

- Remove the hydraulic clutch slave cylinder.

• Clutch pedal must not be operated.

With Automatic Transmission

- Remove the selector lever cable from the transmission.

Continuation for All

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

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

- Remove the right drive axle, and remove the left drive axle from the transmission.

- Remove securing clamps for power steering pressure line.

- Disconnect the power steering pump on its mount and move it to the side; the hoses remain connected.

- Remove the pendulum support bolts in the specified sequence - arrows - shown.





With Air Conditioning

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

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

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

- Remove the generator.

- Remove the oil dipstick inlet spout.

- Remove the A/C compressor.

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





- Remove the subframe.

- Remove the front exhaust pipe => [ Exhaust System Components ] [1][2]Exhaust System Components.

- Insert engine support (T10012) in engine/transmission jack (V.A.G 1383 A).

- Remove the lower coolant hose bracket from the cylinder block. The threaded hole is needed for attaching the engine support ( T10012).

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





- Hand-tighten the engine bracket (T10012) nut on the exhaust system side.

- Slightly lift the engine/transmission jack (V.A.G 1383 A).

- From above, remove the engine mount to engine mount bracket bolts - arrows -.





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

- Remove the transmission mount to transmission mount bracket bolts- arrows B - from above.





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

• Carefully guided engine with transmission, when lowering, to prevent damage to bodywork.

- Carefully lower engine with transmission.

- While doing this, route the power steering pressure line on the transmission.
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