Engine, removing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Identifying Special Tools - Engine, Removing (1 Of 2)

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Special tools, testers and auxiliary items required

Engine sling 2024 A
Engine bracket 3269
Engine bracket 3395
Spark plug connector tool T10029

Holding fixture VW 313
Shop hoist VAG 1202
Drip pan VAG 1306 for VAG 1202 A

Fig 2: Identifying Special Tools - Engine, Removing (21 Of 2)

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Special tools, testers and auxiliary items required

Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Engine/transmission jack VAG 1383 A
Hose clip pliers VAG 1921

Ladder VAS 5085
Lubricating grease G 000 100 (vehicles with manual transmission)
Cable ties

Remove engine together with transmission from below.
When installing, replace all cable ties that have been unfastened or cut during removal of engine at same location.

NOTE:

As work progresses, it will be necessary to disconnect the battery ground strap. Therefore, please check whether a coded radio device has been installed. If so, it may be necessary to obtain the radio anti-theft protection code in advance.

With ignition switched off, disconnect battery ground strap.
Pull spark plug boots with Installation Tool T10029 and detach ignition cables: Refer to 28 IGNITION/GLOW PLUG SYSTEM
Remove engine cover. Refer to 28 IGNITION/GLOW PLUG SYSTEM
Remove battery and battery tray.

Remove air filter assembly: Refer to FUEL INJECTION, SERVICING

Fig 1: Identifying Supply Line And Return Line

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Remove supply hose - 1 - (with white marking) and return hose - 2 - (with blue marking) and catch fuel that flows out with a cleaning rag.

NOTE:

Squeeze the tabs on the hose clamps together.

CAUTION: The fuel system is pressurized. Before opening the system, plane a clean rag around the connection. Then reduce pressure by carefully and slowly loosening the connection.

Plug lines to prevent contamination of fuel system.
Remove center, left and right side sound damping tray: Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW or NOISE INSULATION (DIESEL ENGINES), ASSEMBLY OVERVIEW
Remove "V" ribbed belt, refer to Ribbed V-belt, removing and installing .
Remove power steering pump from its mount and set aside; leave hoses connected: Refer to P.A.S. POWER STEERING PUMP, VEHICLES WITH LOW MOUNTED POWER STEERING PUMP, REMOVING AND INSTALLING or P.A.S. POWER STEERING PUMP, VEHICLES WITH HIGH MOUNTED POWER STEERING PUMP, REMOVING AND INSTALLING

Remove mounting brackets for power steering pressure line.

Vehicles with air conditioning

Observe additional instructions and installation operations, refer to Vehicles with air conditioning, additional notes and assembly work .

Vehicles with manual transmission

Remove shift linkage from transmission: Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING
Remove hydraulic clutch slave cylinder: Refer to 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 02J or 30 - CLUTCH for 6 SPD. MANUAL TRANSMISSION 02Y ALL WHEEL DRIVE

Vehicles with automatic transmission

Remove selector lever cable from transmission: Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 4 SPD. AUTOMATIC TRANSMISSION 01M or SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 5 SPD. AUTOMATIC TRANSMISSION 09A

Continuation for all vehicles

Remove front bumper: Refer to FRONT BUMPER
Put lock carrier into service position: Refer to LOCK CARRIER SERVICE POSITION
Remove intake pipe top section, refer to Cylinder head cover, removing and installing .
Disconnect vacuum and vent hoses from engine.

Remove/disconnect and expose all electrical lines from transmission, alternator and starter.
Disconnect plug connections on following components:

Ignition Coil N152
After-Run Coolant Pump V51
Camshaft Position (CMP) Sensor G40
Cylinder 1 Fuel Injector N30

Cylinder 4 Fuel Injector N33
Cylinder 5 Fuel Injector N83
Cylinder 6 Fuel Injector N84
Engine Coolant Temperature (ECT) Sensor G62

Engine Speed (RPM) Sensor G28
Knock Sensor (KS) 1 G61
Knock Sensor (KS) 2 G66
Heated Oxygen Sensor (HO2S) 1 G39

Oxygen Sensor O2S Behind Three Way Catalytic Converter (TWC) G130

Installation locations: Refer to 24 MULTIPORT FUEL INJECTION (MFI)

Remove/disconnect and uncover from engine any additional electrical lines that may be necessary.
Disconnect vacuum and vent hoses from engine.
Drain coolant, refer to Coolant, draining and filling .
Remove radiator coolant hoses from engine with pliers for spring clamps VAG 1921.

Remove front exhaust pipe, refer to Exhaust system components, removing and installing .
Remove dust boot for inside right constant velocity joint from engine.
Remove right and left drive axles from transmission: Refer to 40 FRONT SUSPENSION

Fig 2: Identifying Pendulum Support & Bolts

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Remove rocker bracket - arrows -.

Fig 3: Identifying Engine Bracket 3395 Slot Dimensions

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Enlarge slot of engine bracket 3395 as shown to dimensions:

a = 32 mm
b = 27 mm

Insert engine bracket 3395 into engine/transmission jack VAG 1383 A.

Fig 4: Identifying Vag 1383 A & Engine Bracket 3395 Attached To Engine With Retaining Nuts

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Attach engine bracket 3395 to engine block and tighten to 40 Nm with retaining nuts - 1 -.
Slightly raise engine and transmission with engine/transmission jack VAG 1383 A.

Fig 5: Locating Engine Carrier Bolts (Engine Side)

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Remove support on engine side from engine bracket - arrows - from above.

NOTE:

Use ladder VAS 5085 to remove retaining bolts.

Fig 6: Locating Engine Carrier Bolts (Transmission Side)

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Remove support on transmission side from transmission bracket - arrows - from above.
Carefully lower engine together with transmission.

NOTE:

When lowering the engine together with transmission, it must be guided carefully in order to prevent damage to the structure.