Volkswagen Workshop Service and Repair Manuals

Note:

During the further course of work the battery earth strap must be disconnected. Therefore please check first whether a coded radio is fitted. Obtain radio code first if necessary.

• ‒ The engine is removed downwards together with the gearbox.

• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing the engine.
• ‒ With the ignition switched off disconnect the battery earth strap.
• ‒ Remove the engine cover.
• ‒ Remove centre as well as the left and right-hand sound insulation:

=> General body repairs, exterior; Repair group 50; Noise insulation (petrol engine) - Assembly overview

• ‒ Drain coolant .
• ‒ Remove battery and battery retainer.

=> Electrical system; Repair group 27; Battery; Removing and installing battery

• ‒ Observe rules for cleanliness .

• ‒ → Pull fuel supply line -1- off union. To do this, press locking ring -2- into the union -3-.
• ‒ Seal the pipes to avoid contamination of the fuel system.
• ‒ Remove intake manifold upper part=> Page 24-24 .

Note:

Seal the intake ports in the intake manifold lower section with clean cloths.

• ‒ In preparation for the further dismantling work disconnect the connectors from the following components:
• Inlet camshaft timing adjustment valve (N205)
• Ignition coils with final output stages (N70, N127, N291, N292)
• Hall sender (G40)
• Injectors (N30...N33), unclip cable guide
• Coolant temperature sender (G62)
• Engine speed sender (G28)
• Knock sensor 1 (G61)
• Knock sensor 2 (G66)
• Secondary air pump motor (V101)
• Oil pressure switch (F1)
• Air mass meter (G70)

• ‒ Remove air cleaner with air mass meter (G70), => page 24-17 .

Models with a manual gearbox

• ‒ Disconnect shift mechanism from gearbox.

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

• ‒ Remove hydraulic clutch slave cylinder:

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

Note:

The clutch pedal must not be operated.

Vehicles with automatic gearbox

• ‒ Remove selector lever cable from gearbox:

=> Automatic gearbox 01M; Repair group 37; Servicing selector mechanism; Removing and installing cable

Continuation for all models

• ‒ Remove poly V-belt => page 13-11 .
• ‒ Remove securing clamps for power steering pressure pipe.

• ‒ Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected:

=> Running gear; Repair group 48; Assembly overview: Vane pump with hydraulic pipes

Vehicles with air conditioning

• ‒ Remove air conditioner compressor.
• ‒ Observe additional information and removal work => page 10-20 .

Continuation for all models

• ‒ Disconnect hoses from engine.
• ‒ Remove bracket for secondary air pump motor.
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.
• ‒ Pull off/disconnect all other electrical connections from engine and lay to one side as necessary.

• ‒ → Unbolt pendulum support -arrows-.
• ‒ Remove protective cover for right-hand inner constant velocity joint from engine.
• ‒ Remove right-hand drive shaft and disconnect left-hand drive shaft at gearbox:

=> Running gear; Repair group 40; Removing and installing drive shafts

• ‒ Remove front exhaust pipe => page 26-1 , Removing and installing parts of the exhaust system.
• ‒ Pull connection for Lambda probe before catalytic converter off (=> Page 26-6 , Fig.1) and free wiring.
• ‒ Remove oil sump protection , fig.2

• ‒ Insert engine bracket T10012 in engine/gearbox jack V.A.G 1383 A.
• ‒ → Secure engine bracket T10012 to front of cylinder block with securing bolt M10 x 25/ 8.8 to 40 Nm.
• ‒ Tighten securing nut on exhaust side hand tight.
• ‒ Lift engine and gearbox lightly using engine/gearbox jack V.A.G 1383 A.

• ‒ → Unbolt engine side of assembly mounting from top of engine carrier -arrows-.

Note:

To remove securing bolts, use step ladder VAS 5085.

• ‒ → Unbolt gearbox side of assembly mounting from top of gearbox carrier -arrows-.
• ‒ Carefully lower engine with gearbox.

Note:

Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines/wiring.