Volkswagen Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Lifting tackle -3033-

t	Hose clamps, up to 25 mm -3094- (for vehicles with manual gearbox)

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Stepladder -VAS 5085-

t	Workshop hoist -VAS 6100-

t  Drip tray for workshop hoist -VAS 6208-

t  Spring-type clip pliers -VAS 6362-

t  Transportation lock -T10403- t  Engine bung set -VAS 6122- (not shown)   Note t  Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding if necessary. t  The engine is removed forwards together with the gearbox. t  All cable ties that are opened or cut through when the engine is removed must be renewed in the same position when the engine is installed.   WARNING 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 and electrical wiring so that they are in their original positions. t  e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid, vacuum. t  Ensure that there is sufficient clearance to all moving or hot components. Removing –  Remove engine cover panel → Chapter. –  With ignition switched off, disconnect earth strap from battery. → Electrical system; Rep. gr.27. –  Remove battery and battery tray → Electrical system; Rep. gr.27.

–  Detach vacuum line -arrow- on brake servo. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50 –  Drain coolant → Chapter. Vehicles with air conditioner –  Extract refrigerant from air conditioning system → Heating, air conditioning system; Rep. gr.87.

–  Unbolt refrigerant lines -arrow- at lock carrier → Heater, air conditioning system; Rep. gr.87. Continuation for all vehicles –  Remove lock carrier → General body repairs, exterior; Rep. gr.50.

–  Pull vacuum line -1- off vacuum pump -2-.

–  Unbolt positive cable -1- at positive distributor on battery. –  During further procedure, lay cable down on engine.

–  Release catches -arrows-, remove air duct -1-.

–  Remove vacuum lines upwards from air filter -1- together with bracket. –  Pull connector off charge pressure control solenoid valve -N75--3-. –  Unbolt charge pressure control solenoid valve -N75- with bracket at -2-. –  Place charge pressure control solenoid valve -N75- with vacuum lines on engine. –  Remove air filter housing with air mass meter and connecting pipe → Chapter. –  Remove engine control unit from its bracket .

–  Release connector for engine wiring harness -arrow- and pull off from engine control unit.

–  Disconnect connectors -arrow-.

–  Carefully loosen engine wiring harness at its fastening points -arrows-. –  Place engine wiring harness on engine.

–  In order to ensure that the vacuum hose -arrow 1- from the brake servo to the engine is not damaged, you must remove it → Rep. gr.47.

Pre-heater line -arrow 2- is not necessarily installed. –  Separate connectors at engine control unit → Chapter.

–  Separate connectors -1- from exhaust gas temperature sender 1 -G235-. –  Separate fuel supply line and return line at fuel transfer point → Chapter. –  Catch any escaping fuel.

–  Using a finger, release lug from fuel pre-heater valve. –  Pull fuel pre-heater valve upwards out of coolant expansion tank guide.

–  Unclip replaceable filter cartridge from lower part of fuel filter. –  Remove replaceable filter cartridge upwards. –  Lay replaceable filter cartridge and fuel hoses together with fuel pre-heater valve on engine. –  Remove fuel filter lower part.

–  Filler neck: Unclip windscreen washer system reservoir -1-. –  Filler neck: Unclip windscreen washer system reservoir -2-. Vehicles with air conditioning system:

–  During further procedure, unscrew securing bolt for refrigerant line -arrow- at air conditioner compressor → Air conditioning system; Rep. gr.87. –  Pull off refrigerant line at air conditioner compressor and lay it aside without kinking. Continuation for all vehicles –  Remove coolant expansion tank and lay down on engine.

–  Unscrew bolt -arrow- (attached), unscrew intake hose -A- clockwise out of its bracket and remove.

–  Disconnect quick-release couplings for heat exchanger -arrows- on plenum chamber bulkhead. –  Remove gear selector mechanism from gearbox → Manual gearbox; Rep. gr.34.

–  Remove bolt -3-. –  Remove hydraulic clutch slave cylinder: → Rep. gr.30.   Note t  Clutch pedal must not be depressed.

t  Remove air hose below on left; first loosen hose clips -1- and -2-. t  Seal open lines and unions with clean plugs from engine sealing plug set -VAS 6122-.

t  Remove air hose below on right; first loosen hose clips -1- and -2-. t  Seal open lines and unions with clean plugs from engine sealing plug set -VAS 6122-. –  Unbolt all lines on gearbox. –  Disconnect all connectors between starter, gearbox and body.

–  Remove right drive shaft cover. –  Remove drive shafts at gearbox → Running gear, axles, steering; Rep. gr.40. –  Tie up drive shafts as high as possible.

–  Remove bolts -2…3-.

–  Remove securing clamp -1- between catalytic converter and turbocharger.

–  Unscrew bolts -1- and nuts -2-. –  Remove catalytic converter bracket. –  Push catalytic converter to side and secure to plenum chamber bulkhead with suitable means.   Note Check that all hose and line connections between engine, gearbox and body have been detached.

–  Use lifting tackle -3033- and workshop crane -VAS 6100- to support »engine/gearbox assembly« in installation position. Vibration damper end: l  Position 2. Flywheel end: l  Position 8.

–  Unbolt engine assembly mounting -arrows- and remove completely.

–  Remove assembly mounting at gearbox. Remove bolts -arrows-.   Note Carefully guide »engine/gearbox assembly« when removing to avoid damage to body. –  Slightly lift »engine/gearbox assembly« and remove forwards. Secure engine to engine and gearbox support -VAS 6095- to carry out repairs → Chapter.