Volkswagen Workshop Service and Repair Manuals

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ The engine is removed forwards together with the gearbox.
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove engine cover.
• ‒ Remove battery
• ‒ Remove battery tray.
• ‒ Disconnect fuel supply and return pipes at fuel filter.
• ‒ Remove connecting pipe between charged air cooler and intake connecting flange.
• ‒ Remove air mass meter/turbocharger connecting pipe.
• ‒ Pull connectors off thermo-switch and radiator fan.
• ‒ Remove noise insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

• ‒ Drain coolant .
• ‒ Pull radiator coolant hoses off engine using spring-type clip pliers V.A.G 1921 or VAS 5024.

Vehicles with air conditioner:

• ‒ Observe additional information and removal instructions => Page 10-14.

• ‒ Removing lock carrier with attachments:

=> General body repairs, exterior; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

• ‒ Remove hydraulic clutch slave cylinder:

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

Note:

Clutch pedal must not be depressed.

• ‒ Disconnect selector mechanism from gearbox.

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

• ‒ Pull vacuum and breather hoses off engine.
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.
• ‒ Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.

• ‒ → Remove pendulum support -1- from gearbox.
• ‒ Unhook charge air cooler/turbocharger connecting pipe at sump and remove.
• ‒ Disconnect drive shafts at gearbox:

=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft

• ‒ Remove ribbed belt => Page 13-16.
• ‒ Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected.

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

• ‒ Unscrew front exhaust pipe from turbocharger.

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane V.A.G 1202 A:

    Pulley end:
    2nd hole in hook at position 1

    Flywheel end:
    4th hole in hook at position 7

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.

• ‒ → Unbolt assembly at gearbox and engine mounting -arrows-.
• ‒ Lower assembly until it is released from the gearbox mounting.
• ‒ Pull assembly out forwards. When doing this, if necessary turn assembly and lower slightly.

Note:

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

• ‒ Secure engine to support clamp VW 313 using engine and gearbox bracket VW 540.