Engine, Removing
Engine, Removing
• If the engine oil must be drained because of work performed on a removed engine, it should be performed with the engine installed. If the engine hangs on the engine lateral bracket (T03001 ), the engine is not in the installed position and less engine oil flows out.
Special tools, testers and auxiliary items required
• Torque wrench (5-50 Nm) (VAG 1331)
• Torque wrench (40-200 Nm) (VAG 1332)
• Engine and transmission jack (VAG 1383A)
• Spring clip pliers (VAS 5024A) or hose clip pliers (VAS 6340)
• Step ladder (VAS 5085)
• Engine holder bracket (T03000)
• Hose clamps up to 25 mm dia. (3094)
• Old oil collecting and extracting device (VAG 1782)
• Adapter set for engine and transmission support (VW 540/1A)
• M8 x 100 bolt
• Cable tie
Secure the engine to the engine stand. Refer to => [ Engine, Securing on Assembly Stand ] Engine, Securing on Assembly Stand.
• To perform the procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, they must be replaced in the same position when installing the engine.
• Seal off the removed fuel, ventilation and vacuum lines so no dirt enters the system.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
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 (for example, fuel, hydraulic, Evaporative Emission (EVAP) system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
- Remove the engine cover.
- Remove the intake hose - 1 - and electrical connector - 2 - from the Mass Air Flow (MAF) sensor.
- Disconnect the hose - 3 - from the air filter housing.
- Remove the bolts - 4 and 6 - and remove the air filter housing.
- Remove the battery.
- Remove the battery holder bolts - arrows - and holder.
CAUTION!
Fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before loosening the line connections, place cloths around the connection point. Then release pressure by carefully loosening the line.
Vehicles Through MY 2009
- Remove the vacuum line - 1 -, ventilation line - 2 - and fuel supply line - 3 - and absorb any leaking fuel with a cleaning cloth.
Vehicles From MY 2010
- Remove the ventilation line - 2 - and fuel supply line - 3 -. Absorb any leaking fuel with a cleaning cloth.
Continuation for All Vehicles
• Press the securing ring in to disengage the lines.
- Disconnect all connectors - 1 - from the fuel injectors as well as connectors - 2 and 7 -.
- Remove the wiring harness - 3 - from the transport strap.
- Open the clamp - 6 - and disconnect the hose.
- Pull all clamps - 4 - and retaining ring - 5 - from locking mechanism.
- Disengage and disconnect connectors from the ignition coils, camshaft adjustment valve 1 (N205), intake manifold, throttle valve control module (J338), Secondary Air Injection (AIR) solenoid valve (N112 ), knock sensors and Engine Coolant Temperature (ECT) sensor (G62).
- Remove the ground (GND) strap bolt at the chain case cover and free up the wiring harness.
Vehicles with a Automatic Transmission
- Disengage the connector from multifunction switch and disconnect.
- Remove the selector lever cable from the transmission.
Vehicles with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Remove the brace - 1 -.
- Remove the slave cylinder - arrows - and set it aside, do not open the line system.
CAUTION!
Do not operate the clutch pedal anymore after the slave cylinder has been removed. The slave cylinder may be damaged by doing this.
- Disconnect the backup light switch connector
Continuation for All Vehicles
- Remove wiring harness from bracket on transmission and from starter.
- Remove vacuum hose from vacuum pump.
- Remove front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Front Exhaust Pipe With Catalytic Converter.
- Disconnect harness connector - 2 - for oxygen sensor in exhaust manifold.
- Remove heat shield at top of front exhaust pipe and free up wiring harness of oxygen sensor in exhaust manifold to engine.
- Remove the right front wheel housing liner.
- Remove the left and right drive axles.
- Remove the rear bolt - arrow - for the engine mount through the wheel housing.
- Remove the pendulum support bolts - arrows -.
- Remove the subframe.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Bring the lock carrier into the service position. Radiator Support
- Support the lock carrier using a sleeve - B -, 80 millimeter (mm) in length, for example, from (VW 540/1 A) and a M8 x 100 bolt - A -.
- Disengage and disconnect connectors from the generator, engine speed sensor and oil pressure switch. Free up the wiring harness.
- Disengage and disconnect both connectors on the front of the transmission.
- Disconnect the power steering line and remove the bracket for the wiring harness on the transmission.
- Remove the nut - 1 - for the line - 2 - for the power steering at the engine and disconnect the line from the threaded pin.
- Remove the coolant expansion tank.
- Empty the power steering reservoir using the (VAG 1782) and remove it.
- Remove the bracket nuts - 2 - for the power steering reservoir.
- Remove the nut - 1 - from the bracket. To do so, remove the right main head lamp.
- Disconnect the intake and pressure line from the power steering pump. Seal the pump and lines with clean plugs.
- Pull the pressure line to the left longitudinal member and securely it firmly.
- Remove the nut - arrow - for the intake line - A - at the engine mount. Remove the intake line.
- Disconnect both coolant hoses from the heater core (quick release couplings).
- Only slightly loosen the bolts of the mounts at the engine and transmission (less than 1 rotation).
Vehicles with Air Conditioning (A/C)
To facilitate removal and installation of the engine without having to open the refrigerant circuit:
- Disconnect the refrigerant line from the right longitudinal member at the top.
- Disconnect the refrigerant line from the right longitudinal member at the bottom. Remove the nuts - 1 and 2 - to do so.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove the A/C compressor from the accessory bracket.
- Secure the A/C compressor - A - to the body so that the refrigerant lines/hoses are not burdened.
• To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the lines/hoses are not stretched, kinked or bent.
Continuation for All Vehicles
- Disconnect/clamp off all other connections - coolant, vacuum and intake hoses from the engine and transmission.
- Install the (T03000) as follows:
• Remove the pin (T03000/1) from (T03000).
• Attach the (T03000) to the cylinder block with pin - 3 - and tighten bolts - 1 and 2 - hand tight.
• Then install the pin (T03000/1) and tighten it to 20 Nm.
• Then tighten bolts - 1 and 2 - to 25 Nm.
- Place the (T03000) on the (VAG 1383A) and lift slightly.
- Remove the engine mount bolts - arrows - from above and remove.
• Use (VAS 5085) to remove the bolts.
- Remove both front bolts from the transmission mount.
- Remove the transmission mount bolts - arrows - from the transmission mount bracket from above.
- Carefully lower the engine with transmission downward and pull it forward while doing so.
- When lowering, guide the exhaust manifold past at the steering gear.