Volkswagen Workshop Service and Repair Manuals

Notes on removing –  First check whether a coded radio is fitted. If so, obtain anti-theft coding. –  The engine is removed downwards together with the gearbox. –  With the ignition switched off, disconnect battery earth strap. –  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. –  Remove engine cover. Vehicles with secondary air system

–  Remove connecting hoses -arrows- between secondary air pump/combination valve and secondary air pump/air cleaner. –  Pull connector -1- off secondary air pump. Continuation for all vehicles –  Remove air cleaner → Chapter. –  Pull vacuum and breather hoses off engine.   WARNING Fuel supply lines are under pressure! Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Pull off supply hose -1- (with white marking) and return hose -2- (with blue marking) and catch fuel that escapes in a cloth. –  Pull hose off solenoid valve -3-.   Note Press buttons on hose couplings to do this. –  Seal lines so that fuel system is not contaminated by dirt. –  Remove intake hose between air mass meter -G70- and throttle valve control module -J338- or turbocharger. Vehicles with turbocharger –  Loosen intake hose (between charge air cooler and throttle valve control module -J338-) at throttle valve control module -J338- and pull off. Vehicles with 5-speed manual gearbox 02C –  Disconnect selector mechanism from gearbox: → Rep. Gr.34. –  Remove hydraulic clutch slave cylinder: → Rep. Gr.30.   Note Clutch pedal must not be depressed. Vehicles with 5-speed manual gearbox 02J   Note Clutch pedal must not be depressed. –  Disconnect selector mechanism from gearbox: → Rep. Gr.34. –  Remove hydraulic clutch slave cylinder: → Rep. Gr.30.   Note Clutch pedal must not be depressed. Vehicles with 6-speed manual gearbox 02M –  Disconnect selector mechanism from gearbox: → Rep. Gr.34. –  Remove hydraulic clutch slave cylinder: → Rep. Gr.30.   Note Clutch pedal must not be depressed. Vehicles with automatic gearbox –  Remove selector lever cable from gearbox: → Rep. Gr.37. Continuation for all vehicles –  Remove noise insulation tray: → Rep. Gr.50. –  Draining coolant → Chapter –  Pull radiator coolant hoses off engine using spring-type clip pliers -VAS 5024A-.

–  Remove pendulum support -arrows-. –  Disconnect all electric wires from gearbox, alternator and starter and lay to side. Vehicles with 5-speed manual gearbox 02C –  Remove front propshaft: → Rep. Gr.39. Continuation for all vehicles –  Remove front exhaust pipe → Chapter. –  Remove poly V-belt → Chapter. –  Remove securing clamps for power steering pressure line. –  Unbolt power assisted steering vane pump from bracket and lay to side, hoses remain connected: → Rep. Gr.48. –  Pull off or disconnect all other electrical connections as necessary from engine and lay clear. –  Remove right drive shaft and disconnect left drive shaft at gearbox: → Rep. Gr.40. Vehicles with air conditioner –  Remove air conditioner compressor: –  Observe additional notes and assembly work → Chapter. Continuation for all vehicles

–  Fit engine bracket -T10012- onto cylinder block with securing nut and M10×25/ 8.8 bolt and tighten to approx. 40 Nm. –  Lift engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A-.

–  From above, unbolt engine side of assembly mounting from engine bracket -arrows-.   Note To remove securing bolts, use stepladder V.A.S -VAS 5085-.

–  Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-. –  Carefully lower engine with gearbox.   Note Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.