Volkswagen Workshop Service and Repair Manuals

Special tools, testers and auxiliary items

• ◆ Lifting tackle 2024 A.
• ◆ Grease G 000 100.
• ◆ Torque wrench V.A.G 1331 (5...50 Nm).
• ◆ Torque wrench V.A.G 1332 (40...200 Nm).
• ◆ Cable tie.
• ◆ Engine bracket VW 540.

Notes on removing

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 from above together with gearbox.
• ‒ All cable ties which is opened or cut open when removing engine, must be replaced in the same position when installing the engine.

Work sequence

• ‒ With ignition switched off disconnect battery earth strap.
• ‒ Remove air cleaner housing complete.
• ‒ Drain coolant .
• ‒ Disconnect clutch cable.
• ‒ Disconnect all coolant, vacuum and breather hoses from engine.
• ‒ Disconnect all electric wires from gearbox, engine, starter and alternator and move clear.
• ‒ Remove radiator together with fan housing.
• ‒ Disconnect throttle cable.
• ‒ Disconnect speedo cable.
• ‒ Disconnect both drive shafts from gearbox and tie-up.

Vehicles with air conditioning:

• ‒ Observe additional information => Page 10-6.

• ‒ → 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 carrier bar must be towards the pulley end.
• ◆ The holes in the hooks are counted up from the hook.
• ◆ When lifting out the assembly 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 engine bracket VW 540.