Volkswagen Workshop Service and Repair Manuals

Removing engine Securing engine to assembly stand → Chapter.   Note t  Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain radio code first if necessary. t  The engine is removed downwards together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all types of lines (e.g. for fuel, hydraulics, active charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. Gr.27 –  Remove engine cover. –  Remove air filter housing with connecting hoses.

–  Remove battery and battery tray -arrows-. –  Remove top part of intake manifold. –  Remove plenum chamber bulkhead → General body repairs, exterior; Rep. Gr.50 –  Detach connectors from the following components: t  Ignition transformer -N152- t  Injector for cylinder 1 -N30- t  Injector for cylinder 2 -N31- t  Injector for cylinder 3 -N32- t  Injector for cylinder 4 -N33- t  Coolant temperature sender -G62- t  Engine speed sender -G28- t  Knock sensor 1 -G61- t  Knock sensor 2 -G66- t  Secondary air pump motor -V101- t  Oil pressure switch -F1- t  Throttle valve control module -J338- t  If necessary  A/C system shutoff thermal switch -F163- –  Pull engine wiring harness connector off engine control unit. –  Separate all connectors between engine wiring harness and body and lay engine wiring harness on engine.   WARNING The fuel supply line is under pressure! Wear protective glasses and clothing to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Disconnect breather line -1-and fuel supply line -2-. –  Remove noise insulation tray → General body repairs, exterior; Rep. Gr.50 –  Bring lock carrier into service position → General body repairs; Rep. Gr.50. –  Drain coolant → Chapter. –  Remove left wheel housing liner.

–  Unbolt heat shield for right-hand drive shaft -arrows-. –  Remove right drive shaft and then left drive shaft at gearbox → Running gear, axles, steering; Rep. Gr.40.

–  Remove securing nuts -arrows- for front exhaust pipe/exhaust manifold and pull front exhaust pipe off exhaust manifold.

–  Remove bolts -1, 2 and 3- and remove pendulum support. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connection, coolant, vacuum and intake hoses from engine. Vehicles with air conditioning   Note To prevent damage to condenser or to refrigerant pipes and hoses, ensure that pipes and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening refrigerant circuit: –  Remove poly V-belt → Chapter. –  Separate air conditioner compressor from compact bracket → Heating, air conditioning; Rep. Gr.87. –  Secure air conditioner compressor to lock carrier so that refrigerant lines are free of stress. Vehicles with manual gearbox –  Remove selector mechanism from gearbox → Manual gearbox; Rep. Gr.34.

–  Remove strut -1-. –  Remove slave cylinder -arrows- and lay to side. Do not open hydraulic system.   Caution Do not operate clutch pedal after slave cylinder has been removed. This can damage the slave cylinder. Vehicles with automatic gearbox –  Disconnect selector lever cable from gearbox → Automatic gearbox 09G; Rep. Gr.37. All vehicles (continued): –  Insert engine bracket -T10012- in engine-/gearbox jack -V.A.G 1383/A-.

–  Fit engine bracket -T10012- to front of cylinder block with M10x25/ 8.8 bolt. –  Tighten securing nut exhaust side by hand. –  Lift engine and gearbox slightly using engine-/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 -VAS 5085-.

–  From above, unbolt gearbox side of assembly mounting from gearbox bracket -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.