Engine, removing
WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2006 Volkswagen Golf, 2005 Volkswagen Jetta, 2005 Volkswagen Golf, 2004 Volkswagen Jetta, and 2004 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
- To perform work, the Ground (GND) cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.
- The engine is removed downward together with the transmission.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
CAUTION:
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
- Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
- Ensure sufficient clearance to all moving or hot components.
Work procedure
- With ignition switched off disconnect battery Ground (GND) strap.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
- Remove engine cover.
- Remove battery and battery holder.
- Remove air filter.
- Remove sound dampening tray
- For vehicles with turbocharger. Unclamp connecting pipe between charge air cooler and exhaust pipe at exhaust pipe.
CAUTION:
- The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
- In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
- Wear protective goggles and protective gloves when working on the fuel system!
- Clamp off fuel supply line and return line at fuel filter.
- Remove slave cylinder for hydraulic clutch: Refer to 30 CLUTCH
- Disconnect selector mechanism from transmission: Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING
- Vehicles with automatic transmission: Disconnect selector lever cable from transmission: Refer to 37 AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 01M Transmissions, or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 09A transmissions
- Remove noise insulation pan, along with left and right sides: Refer to 50 BODY, FRONT
- Drain engine coolant.
- Remove connectors from thermal switch and radiator fan.
- Disconnect radiator coolant hoses at engine with hose clip pliers V.A.G 1921.
- Remove pendulum support bolts - arrows -.
- Disconnect vacuum and breather hoses from engine.
- Disconnect generator and starter wiring from transmission, and move them to one side for clearance.
- On vehicles with all-wheel drive, remove front driveshaft tube: Refer to 39 FINAL DRIVE, DIFFERENTIAL for 01M transmissions, or 39 - FINAL DRIVE, DIFFERENTIAL for 09A transmissions
- Remove exhaust pipe
- Remove ribbed belt.
- Remove power steering pump from bracket and place to side; hoses remain connected: Refer to 48 STEERING
- Disconnect all electrical connections as necessary from engine and lay aside.
- Remove right drive axle and unbolt left drive axle at transmission: Refer to 40 FRONT SUSPENSION
- Remove securing clamps for power steering pressure line.
- Set engine/transmission support T10012 onto engine/transmission jack V.A.G 1383 A.
- Fasten engine/transmission support T10012 to cylinder block with nut and bolt M10x25/ 8.8 to approx. 40 Nm.
- Slightly lift engine and transmission using engine/transmission jack V.A.G 1383 A.
- Remove engine mount (engine side) from engine bracket - arrows - working from above.
NOTE:
- Use step ladder VAS 5085 to remove bolts.
- Remove engine/transmission mount from transmission bracket - arrows - working from above.
- Carefully lower engine/transmission assembly.
- While lowering, carefully guide power steering lines past transmission.
NOTE:
- Carefully guide engine with transmission, when lowering, to prevent damage to the body.