Engine, removing
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 Volkswagen Jetta, 2002 Volkswagen GTI, 2001 Volkswagen Jetta, 2001 Volkswagen GTI, and 2000 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
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
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
- 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
- Remove rocker bracket - arrows -.
- 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.
- 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.
- Remove support on engine side from engine bracket - arrows - from above.
NOTE:
- Use ladder VAS 5085 to remove retaining bolts.
- 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.