Engine, removing
WARNING: This page is about a different variant/trim than selected.
Work sequence
The engine is removed downward together with the transmission.
CAUTION:
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
- Route all the various lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
- Ensure that there is sufficient clearance to all moving or hot components.
NOTE:
- All cable ties which are opened or cut through when engine is removed must be replaced in the same position when the engine is installed.
- Check whether a coded radio is installed. If so, obtain anti-theft coding.
- With ignition switched off disconnect battery Ground (GND) strap.
- Remove engine cover.
- Remove battery and battery retainer.
- Remove air cleaner.
- Disconnect pipe between charge air cooler and intake connecting flange at intake connecting flange.
- Disconnect fuel supply and return lines at fuel filter.
CAUTION:
- The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
- The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen the connection to release the pressure!
- Wear eye and hand protection when performing any type of repair work on the fuel system!
Vehicles with manual transmission 02J
- Remove hydraulic clutch slave cylinder: Refer to 30 CLUTCH
- Disconnect shift mechanism from transmission: Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING
Vehicles with automatic transmission
- Remove selector lever cable from transmission: refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
Continuation for all vehicles
- Remove center, left and right sound insulation trays: Refer to 50 BODY, FRONT
- Drain coolant, refer to Coolant, draining and filling .
- Disconnect connector from thermal switch and coolant fan.
- Pull coolant hoses off radiator.
- Disconnect all electrical wiring from transmission, Generator and starter and move clear.
- Unbolt pendulum support in order shown - arrows -.
- Remove front exhaust pipe refer to Exhaust system components, removing and installing .
- Remove poly V-belt refer to Poly V-belt, removing and installing .
- Unbolt power steering pump from bracket and move aside. Hoses remain connected: Refer to 48 STEERING
- Separate all connections from engine for coolant, vacuum and intake hoses.
- Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.
- Remove right side axle shaft and disconnect left side axle shaft at transmission: Refer to 40 FRONT SUSPENSION
- Remove securing clamps for power steering pressure line.
Vehicles with air conditioning
- Observe additional information and removal work refer to Additional information and removal work on vehicles with air conditioning .
Continuation for all vehicles
- Insert engine bracket T10012 in engine/transmission jack V.A.G 1383 A.
- Install engine bracket T10012 onto cylinder block with a securing nut and M10x25/ 8.8 bolt and tighten to approx. 40 Nm.
- Lift engine and transmission lightly using engine/transmission jack V.A.G 1383 A.
- Unbolt engine side of assembly mounting from engine carrier at top - arrows -.
NOTE:
- To remove securing bolts use step ladder VAS 5085.
- Unbolt transmission side of assembly mounting from transmission carrier at top - arrows -.
- Carefully lower engine with transmission.
NOTE:
- The engine and transmission must be guided carefully when lowering to prevent damage to the bodywork.