Engine, Removal

Engine, removing and installing

Special tool and equipment







- VW 313 Support clamp
- VW 540 Engine and transmission support
- 2024 A Lifting tackle
- 3180 Retainer (for turbocharged engines)
- V.A.G 1202 A Workshop crane
- V.A.G 1306 Drip tray
- V.A.G 1331 Torque wrench (5 to 50 Nm)
- V.A.G 1332 Torque wrench (40 to 200 Nm)
- V.A.G 1383A Engine/transmission jack
- T10012 Engine bracket
- VAS 5024 Assembly tool for spring-type clamps
- VAS 5085 Step ladder (not shown)
- G 000 100 Grease (vehicles with manual transmission) (not shown)
- Bolt M10X25/8.8 (not shown)
- Cable tie (not shown)

Removal notes
- Check whether a coded radio is installed. If so, obtain the anti-theft coding.
- The engine is removed downwards together with the transmission.
- With ignition switched off disconnect battery Ground 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 connecting hoses-arrows-between secondary air pump/combi-valve and secondary air pump/air cleaner.

Note: Press buttons on hose couplings to remove connecting hoses.

- Pull connector -1- off secondary air pump.
- Remove air filter. Air Cleaner Housing
- Pull vacuum and breather hoses off engine.

WARNING! Fuel supply lines are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.





- Pull off supply line/hose -1- (with white marking) and return line/hose -2- (with blue marking) and collect fuel that leaks out with a cloth.
- Pull hose off solenoid valve.

Note: Press buttons on hose couplings to do this.

- Seal the lines so that the fuel system is not contaminated by dirt etc.
- Remove intake hose between air mass meter (G70) and turbocharger.
- Release intake hose (between charge air cooler and throttle valve control part) on throttle valve control part and pull off.

Vehicles with manual transmission
- Disconnect selector mechanism from transmission. Shift Linkage
- Remove hydraulic clutch slave cylinder.

Note: Clutch pedal must not be depressed.

Vehicles with automatic transmission
- Remove selector lever cable from transmission. Shift Linkage

Continued for all vehicles
- Remove sound insulation tray. Sound Proofing / Insulation
- Drain coolant. Cooling System
- Disconnect coolant hoses from radiator at engine.

Note: The VAS 5024 assembly tool or V.A.G 1921 pliers are recommended for installing the spring-type clamps.





- Remove pendulum support -arrows-.
- Disconnect all electric wires from transmission, generator and starter and move clear.
- Remove front exhaust pipe. Exhaust System
- Remove ribbed belt. Drive Belt
- Remove securing clamps for power steering pressure line.
- Remove power steering pump with bracket and set to one side: hoses remain connected. Power Steering Pump
- Pull off/disconnect all other electrical connections as necessary from engine and move to side.
- Remove right and left drive axles at transmission. Axle Shaft Assembly

Vehicles with air conditioner
- Remove air conditioner compressor. Compressor HVAC
- Observe additional notes and assembly work

Continued for all vehicles





- Install engine bracket T 10012 onto cylinder block with a securing nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm.
- Lift engine and transmission slightly using engine/transmission jack V.A.G 1383 A.





- Remove engine side of assembly mounting from engine support at top -arrows-.

Note: To remove securing bolts use ladder VAS 5085 or equivalent..





- Remove subframe mount from transmission bracket -arrows- on transmission side from above
- Carefully lower engine with transmission.

Note: Engine with transmission must be guided carefully when lowering to prevent damage to the bodywork.