Volkswagen Workshop Service and Repair Manuals

Removing engine Securing engine to assembly stand → Chapter.   Note t  Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. t  The engine is removed downwards together with the gearbox. t  All cable ties which are opened or cut through when the engine is removed must be replaced in the same position when the engine is installed.   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. Gr.27

–  Remove engine cover, if fitted.

–  Unscrew bolt -3- and remove air filter housing with connecting hoses.

–  Remove battery and battery tray. –  Remove plenum chamber bulkhead → General body repairs, exterior; Rep. Gr.50 –  Pull engine wiring harness connector off engine control unit.

–  Release retainer for engine wiring harness -arrow- and pull off upwards.

–  Unscrew cable from alternator -arrow- at fuse holder.

–  Unscrew earth cable from longitudinal member -arrow-.

–  Open wiring guide catches on longitudinal member -arrows-. –  Separate all connectors between engine wiring harness and body and lay engine wiring harness on engine.   WARNING The fuel supply line is pressurized! Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect breather line -1-, fuel supply line -2- and fuel return line -3-. Do this by operating release buttons.   Note The fuel return line -3- is only installed for engine code AXW. –  Remove noise insulation → General body repairs, exterior; Rep. Gr.50. –  Bring lock carrier into service position → General body repairs; Rep. Gr.50. –  Drain coolant → Chapter. –  Remove front left wheel housing liner → General body repairs, exterior; Rep. Gr.66.

–  Unscrew bracket for exhaust system -arrows-. Vehicles with front-wheel drive:

–  Unbolt heat shield for drive shaft (right-side) -arrows-. Continuation for all vehicles: –  Remove right drive shaft and remove left drive shaft from gearbox → Running gear, axles, steering; Rep. Gr.40

–  Remove securing nuts -arrows- for front exhaust pipe/exhaust manifold and pull front exhaust pipe off exhaust manifold. Vehicles with four-wheel drive: –  Remove front propshaft → Final drive 02D, 0AV; Rep. Gr.39. Continuation for all vehicles:

–  Unscrew bolts -1...3- and remove pendulum support.

–  Pull air intake hose -arrow- off bottom of damping chamber and remove it. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with air conditioning:   Note To prevent damage to condenser or to refrigerant lines and hoses, ensure that lines and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening refrigerant circuit: –  Remove poly V-belt → Chapter. –  Separate air conditioner compressor from compact bracket: → Heating, air conditioning; Rep. Gr.87. –  Secure air conditioner compressor to lock carrier so that refrigerant lines are free of stress. Vehicles with manual gearbox –  Remove selector mechanism from gearbox → Manual gearbox; Rep. Gr.34.

–  Remove support -1-. –  Remove slave cylinder -arrows- and lay to side. Do not open hydraulic system.   Caution Do not press clutch pedal after removing slave cylinder. This can damage the slave cylinder. Vehicles with automatic gearbox –  Disconnect selector lever cable from gearbox → Automatic gearbox 09G; Rep. Gr.37. Continuation for all vehicles:

–  Disconnect electrical connector -1- from bracket. –  Unscrew bolts -2 ... 4-. –  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.

–  Set engine bracket -T10012- on engine as shown and bolt to cylinder block to 20 Nm.

–  Bolt engine bracket -T10012- to cylinder block -arrow- through intake manifold support using securing bolt M10x25 with about 20 Nm torque. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.

–  Unbolt engine side of assembly mounting from engine bracket from above -arrows-.

–  Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-.   Note t  To remove securing bolts, use stepladder -VAS 5085-. t  Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork. –  Carefully lower engine with gearbox.