Volkswagen Workshop Service and Repair Manuals

• ‒ The engine is removed forwards together with the gearbox.
• ‒ With ignition switched off disconnect battery earth strap.

Note:

If necessary the anti-theft coding for the radio must be obtained first.

• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove air filter housing with intake hoses.
• ‒ Loosen P.A.S. reservoir hose clamp.
• ‒ Unbolt P.A.S. hydraulic pipe retainers from engine carrier and gearbox.
• ‒ Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected.

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes

• ‒ Drain coolant
• ‒ Removing lock carrier with attachments:

=> General body repairs; Repair group 50; Lock carrier; Removing and installing lock carrier with grille

• ‒ Remove radiator fan and air guide housing.

Vehicles with air conditioner:

• ‒ Observe additional information and removal instructions => Page 10-15 .

Vehicles with manual gearbox

• ‒ Remove hydraulic clutch slave cylinder:

=> 5-Speed manual gearbox 02A; Repair group 30; Servicing clutch control

• ‒ Disconnect selector mechanism from gearbox.

=> 5-Speed manual gearbox 02A; Repair group 34; Servicing selector mechanism

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

• Pulley end:
  4th hole in hook at position 1
• Flywheel end:
  2nd hole in hook at position 6

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

Vehicles with automatic gearbox

• ‒ → Attach lifting tackle 2024A as follows and lift slightly with workshop crane:

     Pulley end:
     2nd hole in hook at position 1

• Flywheel end:
  2nd hole in hook at position 5

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

Continuation for all vehicles

• ‒ → Disconnect engine carrier and on one side lever out distance bracket from rubber mounting.
• ‒ Take out P.A.S. hydraulic pipes from disconnected engine carrier.
• ‒ Lever out assembly forwards.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.

When working on the engine, it should be secured to the engine stand using the engine bracket VW 540.