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)
• Shop Crane (V.A.G 1202 A) or Shop Crane (VAS 6100)
• Drip tray (V.A.G 1306) or drip tray for workshop crane (VAS 6208)
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1332)
• Engine/transmission jack (V.A.G 1383 A)
• Hose clip pliers VAS 6362
• Spacers (VW 540/1 B)
• Grease (G 000 100) (Vehicles with manual transmission)
Special tools, testers and auxiliary items required
• Step ladder (VAS 5085)
• Hose clamps up to 25 mm diameter (3094)
Perform the following:
- Check the DTC memory for all control modules with the => Vehicle Diagnosis Tester before removing.
• To perform work sequence, the Ground cable must be disconnected from battery. Check if 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.
• Seal off the disconnected fuel and ventilation lines to prevent dirt from getting into the system.
• Leave the key in the ignition lock. This prevents the steering lock from engaging.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
- Open clamps - 1 -, - 2 -, - 3 - and - 9 -, and remove intake hose - 10 -.
- Remove the brake booster vacuum hose - 5 - from the intake manifold.
- Remove the air filter. Refer to => [ Air Filter, Assembly Overview ] Service and Repair.
- Remove the battery and the battery tray.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.
- Remove the E-box cover inside the engine compartment - arrows -.
- Disconnect the line - 2 - and free it up.
- Disconnect the connector - 1 - from the engine control module and free up the engine wiring harness. Refer to => [ Engine Control Module, Removing and Installing ] Service and Repair.
- Disconnect the connector - 4 -, open the locking mechanism and lay the engine wiring harness - 3 - on the engine.
- Disconnect the ground cable - 1 - and the starter connections - 2 - and - 5 -.
Vehicles with an automatic transmission
- Disconnect connector - 6 - from multi-function switch.
- Remove selector lever cable from transmission.
- Disconnect the connectors - 1 - and - 2 - from the transmission.
Vehicles with a manual transmission
- Remove the gearshift mechanism from the transmission.
- Remove brace - 1 -.
- Remove the clutch slave cylinder - arrows - and lay it to the side. To not open the line system.
Do not press the clutch pedal after removing the slave cylinder. Slave cylinder may be damaged by doing this.
- Disconnect connector for back-up light switch from transmission.
Continuation for all vehicles
- Disconnect the heated oxygen sensor (G39) connector on the bulkhead and free up the wiring harness. Refer to => [ (Item 14) electrical connector ] Component Locations Overview.
- Remove the coolant hoses from the heat exchanger - arrows -.
- Open the spring clamps - arrows - and remove the coolant hoses from the radiator.
- Disconnect the coolant hoses from the coolant reservoir.
- Remove the air shroud with the radiator fans. Refer to => [ Coolant Fan and Coolant Fan 2, Removing and Installing ] Service and Repair.
Fuel system is under pressure!
• Wear protective goggles and protective clothing in order to avoid injury and contact with the skin.
• Before loosening line connections, place cloths around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect fuel supply line - 1 -. Push the locking ring upward and into the housing.
- Disconnect vent line - 2 -. Press the locking ring.
- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Remove the front exhaust pipe. Refer to => [ Exhaust Manifold, Front Exhaust Pipe with Catalytic Converter and Attachments Assembly Overview ] Service and Repair.
- Remove the driveshafts
- Remove the left driveshaft from the transmission and tie it up.
- Remove the bolt - 1 -.
- Then remove the bolts - 2 - and - 3 -.
- Remove the pendulum support.
- Remove ribbed belt => [ Ribbed Belt, Removing and Installing ] Service and Repair.
- Remove the clamps for the power steering pressure line from the transmission.
- Remove power steering pump from sub-assembly bracket and set it down at the front.
• The power steering pressure line remains connected to the power steering pump.
- Remove the bolt - 3 - and remove the ribbed belt tensioning damper - 2 -.
- Remove the third bolt from the power steering fluid reservoir bracket (not illustrated).
- Move the power steering fluid reservoir, with the hoses - 1 - and bracket still connected, to the side.
Vehicles with A/C
- Remove the A/C compressor, with the refrigerant hoses still connected, from the auxiliary component bracket. Refer to => [ Air Conditioning Additional Information and Procedures ] Air Conditioning Additional Information and Procedures.
Continuation for all vehicles
- Insert the engine support (T10012) in engine/transmission jack (V.A.G 1383 A).
- Attach the engine/transmission support (T10012) to the cylinder block. Tighten the nut - 2 - and the bolt - 1 - to 20 Nm.
- Install the engine/transmission jack (V.A.G 1383 A) in the engine/transmission support (T10012).
- Gently lift engine and transmission using Engine/Transmission Jack (V.A.G 1383 A).
Use a step ladder (VAS 5085) to remove the bolts from the engine/transmission mount.
- Remove the engine mount from the engine support from the top - arrows -.
- Remove the transmission mount from he transmission holder - arrows -.
• Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.
• A 2nd technician is needed to lower the engine/transmission subassembly.
• The engine/transmission subassembly must be guided with care to prevent damage while lowering.
- Carefully lower the engine/transmission subassembly. When doing this, rotate or push the engine/transmission subassembly.
Engine, Securing on Assembly Stand
Perform the following:
Secure the engine to the holding fixture (VW 313) using the engine/transmission holder (VW 540) and the supplemental set (VW 540/1 B).
Procedure
- Remove the transmission from the engine.
Vehicles with an automatic transmission
- Support the torque converter to keep it from "falling down", after separating the engine from the transmission.
Continuation for all vehicles
Use locking pins at the hooks and drifts so that the engine cannot slip or move.
- Engage Engine Sling (2024 A) as follows and lift out using Shop Crane from Engine/Transmission Jack (V.A.G 1383 A).
Belt pulley side:
• 3. Bore of the hole rail in position 2
Transmission side:
• 3. Bore of the hole rail in position 8
• The peg positions on the carrying strap marked 1 to 4 face the belt pulley.
• The bores in the hole rail are counted from the hook.
- Mount the engine to the holding fixture (VW 313) using the engine/transmission holder (VW 540) and spacer (VW 540/1B). Remove the alignment sleeves to do this.
The engine can also be secured to the engine/transmission holder (VAS 6095).