Engine, Removing And Installing
Engine, removing and installing
Special tools, equipment, testers, measuring instruments and auxiliary items required
^ 2024A Lifting tackle
^ T10012 Engine bracket
^ VW313 Support clamp
^ VW540 Engine and transmission support
^ VAG1202A Workshop crane
^ VAG1306 Drip tray
^ VAG1331 Torque wrench (5...50 Nm)
^ VAG1332 Torque wrench (40...200 Nm)
^ VAG1383A Engine/transmission jack
^ VAS5024 Assembly tool for spring-type clips
^ VW540/1B Supplementary set
^ VAS5085 Step ladder
^ G 000 100 Grease (vehicles with manual transmission)
^ Bolt M10x25/8.8
^ Cable tie
Engine removal notes
CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
Note: During the further course of work the battery Ground strap must be disconnected. Therefore, please check whether a coded radio is installed. Obtain the radio code first, if necessary.
^ Interrogate fault memories of all control modules before removing engine:
Refer to Diagnostic tester VAS5051; Guided fault finding; Vehicle system test or VAS5052; Vehicle self-diagnosis
Note: Some components in this vehicle cannot be removed or are very difficult to remove when the engine is installed in the engine compartment. For this reason determine which components are faulty before starting to remove components and replace the faulty components once they have been removed.
^ 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 the engine.
^ With ignition switched off disconnect battery Ground strap.
^ Remove engine cover.
^ Remove power steering fluid reservoir from battery support but do not disconnect/open hoses.
^ Tie reservoir to lock support.
^ Remove battery and battery retainer,
^ Observe rules for cleanliness.
WARNING:
^ Fire Hazard! Do NOT have anything in the area that can ignite fuel!
^ Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
Engine codes AEG, AVH, AZG
^ Pull fuel supply line -1- as well as fuel return line -2- off fuel rail and collect fuel that leaks out with a clean cloth.
^ Pull hose off Evaporative Emissions (EVAP) canister purge regulator valve -N80-.
Engine code BDC
^ Pull fuel supply line -1- as well as fuel return line -2- off fuel rail and collect fuel that leaks out with a clean cloth.
^ Pull hose off Evaporative Emissions (EVAP) canister purge regulator valve -N80-.
Engine codes BEV, BGD
^ Pull fuel supply line -1- off union by pressing locking ring -2- into union -3- and collect fuel that leaks out with a clean cloth.
Continuation for all models
^ Seal lines to avoid contamination of fuel system.
^ Pull vacuum and breather hoses off engine.
^ Remove air cleaner with intake hose and Mass Air Flow (MAP) -G70-.
^ Remove intake manifold upper part.
Note: Seal the intake ports in the intake manifold lower section with clean cloths.
Vehicles with manual transmission
^ Disconnect shift mechanism from transmission.
^ Remove hydraulic clutch slave cylinder:
Note: The clutch pedal must not be operated.
Vehicles with automatic transmission
^ Remove selector lever cable from transmission:
Continuation for all models
^ Remove insulation tray.
^ Drain coolant
^ Remove ribbed belt
^ Remove supplementary coolant fan on right side of vehicle, if part of original equipment.
^ Remove power steering pressure line securing clamps on engine and transmission.
^ Remove power steering pump from bracket and tie up to front panel; hoses remain connected:
Vehicles with air conditioning
^ Remove air conditioning compressor:
Continuation for all models
^ Disconnect inter-connecting, coolant, vacuum and intake lines on engine.
^ Separate connections on following components:
Ignition coils -N- and -N 128- with
Final output stage -N122- or Ignition coils with
Final output stage -N70-, -N 127-, -N291 -; -N292
Camshaft Position (CMP) sensor-G40
Injectors -N30-...-N33-, release cable guide
Engine Coolant Temperature (ECT) sensor -G62
Engine speed (RPM) sensor -G28
Knock Sensor (KS) 1 -G61
Knock Sensor (KS) 2 -G66
Secondary Air Injection (AIR) pump motor -V101
Oil pressure switch -F1
If installed, A/C cut-out thermal switch -F163
Mass Air Flow (MAP) sensor -G70
Throttle valve control module -J338
^ Unbolt secondary air injection pump and bracket and remove.
^ Disconnect all electric wires from transmission, Generator and starter and move clear.
^ Disconnect all other electrical connections as necessary from engine and lay to one side.
^ Unbolt pendulum support (arrows).
^ Remove protective cover for right side inner constant velocity joint from engine.
^ Remove right side axle shaft and disconnect left-hand drive shaft at transmission:
^ Remove front exhaust pipe.
^ Disconnect connection for oxygen sensor before catalytic converter (under vehicle floor).
^ Remove oil sump protection
^ Insert engine bracket T10012 in engine/transmission jack VAG1383A.
^ Remove bracket on cylinder block for lower coolant hose. Threaded hole is required to secure engine bracket T10012.
^ Secure engine bracket T10012 to front of cylinder block with securing bolt M10x25/ 8.8 to 40 Nm.
^ Tighten securing nut on exhaust side hand tight.
^ Lift engine and transmission lightly using engine/transmission jack VAG1383A.
^ Unbolt engine side of assembly mounting from engine carrier at top (arrows).
Note: Use ladder VAS5085 to remove securing bolts.
^ Unbolt transmission side of assembly mounting from top of transmission carrier (arrows).
^ Carefully lower engine with transmission.
^ While lowering engine guide power steering pressure line past transmission.
Note: Engine and transmission must be guided carefully when lowering to prevent damage to the bodywork, hoses and wiring.
Engine, mounting on assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW313 using the engine and transmission bracket VW540 and supplementary set VW540/1B.
Work sequence
^ Move engine/transmission assembly to a work bench with jack VAG1383A.
^ Lower engine/transmission assembly so that transmission is on work bench.
^ Remove engine/transmission connecting bolts.
^ Press off transmission.
Vehicles with automatic transmission
^ Remove nut from torque converter.
^ Remove hoses from ATF cooler.
^ Seal off ATF cooler with clean plugs.
^ Secure torque converter against falling out after separating engine from transmission.
Continuation for all models
^ Attach lifting tackle 2024A as follows and lift off engine/transmission jack VAG1383A with workshop crane.
Pulley end: 3rd hole of lifting rail in position 2
Flywheel end: 3rd hole of lifting rail in position 8
CAUTION: Hooks and locating pins must be secured with locking pins.
Note:
^ Positions marked 1...4 on the bar must face toward belt pulley end.
^ The holes in the hook rails are counted up from the hook.
^ Secure engine to support clamp VW313 using engine and transmission bracket VW540 and supplementary set VW540/1B. Dowel sleeves must be removed.
Engine installation notes
Installation is performed in the reverse sequence, Note the following:
WARNING: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
^ Insert new dowel sleeves in cylinder block for centralizing engine and transmission.
^ Fit intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).
Vehicles with manual transmission
^ Lightly grease input shaft splines with G 000 100 grease.
^ Check clutch and clutch operating mechanism, then install.
^ Install gear shift mechanism, adjust gear shift cables if necessary:
Vehicles with automatic transmission
^ Install selector cable on transmission, adjust if necessary:
^ Install selector cable on transmission, adjust if necessary:
Note: Always replace selector cable circlip
Vehicles with air conditioning
^ Install air conditioning compressor:
Continuation for all models
^ When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
^ When doing this guide power steering pressure line past transmission.
^ Align assembly mountings for engine and transmission.
Note: Torque settings; Refer to Engine , Specifications, Mechanical; Tightening Torques
^ Install right side axle shaft and attach left side axle shaft to transmission:
^ Install front exhaust pipe
^ Install power steering pump:
^ Reconnect electrical connections and check routing:
^ Install ribbed belt.
^ Install secondary air injection pump.
^ Install center, left and right insulation trays:
^ Fill system with coolant.
Vehicles without EPC
^ Adjust accelerator cable.
Vehicles with EPC
^ Adapt (match) engine control module to throttle valve control
Continuation for all models
^ If fault memory has been erased or engine control module was disconnected from permanent positive, respective components must be adapted to engine control module and readiness code generated again.
^ Road test vehicle and interrogate all fault memories:
Refer to Diagnostic tester VAS5051; Guided fault finding; Vehicle system test
Observe the valid safety precautions when performing a road test.
^ Read readiness code.
Vehicles with automatic transmission
^ Adapt transmission control module:
^ Test drive vehicle and interrogate fault memory.
Engine, mounting on assembly stand
When working on the engine, it should be secured to the assembly stand support clamp VW313 using the engine and transmission bracket VW540 and supplementary set VW540/1B.
Work sequence
^ Move engine/transmission assembly to a work bench with jack VAG1383A.
^ Lower engine/transmission assembly so that transmission is on work bench.
^ Remove engine/transmission connecting bolts.
^ Press off transmission.
Vehicles with automatic transmission
^ Remove nut from torque converter.
^ Remove hoses from ATF cooler.
^ Seal off ATF cooler with clean plugs.
^ Secure torque converter against falling out after separating engine from transmission.
Continuation for all models
^ Attach lifting tackle 2024A as follows and lift off engine/transmission jack VAG1383A with workshop crane.
Pulley end: 3rd hole of lifting rail in position 2
Flywheel end: 3rd hole of lifting rail in position 8
CAUTION: Hooks and locating pins must be secured with locking pins.
Note:
^ Positions marked 1...4 on the bar must face toward belt pulley end.
^ The holes in the hook rails are counted up from the hook.
^ Secure engine to support clamp VW313 using engine and transmission bracket VW540 and supplementary set VW540/1B. Dowel sleeves must be removed.
Engine installation notes
Installation is performed in the reverse sequence, Note the following:
WARNING: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.
^ Insert new dowel sleeves in cylinder block for centralizing engine and transmission.
^ Fit intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).
Vehicles with manual transmission
^ Lightly grease input shaft splines with G 000 100 grease.
^ Check clutch and clutch operating mechanism, then install.
^ Install gear shift mechanism, adjust gear shift cables if necessary:
Vehicles with automatic transmission
^ Install selector cable on transmission, adjust if necessary:
^ Install selector cable on transmission, adjust if necessary:
Note: Always replace selector cable circlip
Vehicles with air conditioning
^ Install air conditioning compressor:
Continuation for all models
^ When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
^ When doing this guide power steering pressure line past transmission.
^ Align assembly mountings for engine and transmission.
Note: Torque settings; Refer to Engine, Specifications, Mechanical, Torque Settings
^ Install right side axle shaft and attach left side axle shaft to transmission:
^ Install front exhaust pipe.
^ Install power steering pump:
^ Reconnect electrical connections and check routing:
^ Install ribbed belt.
^ Install secondary air injection pump.
^ Install center, left and right insulation trays:
^ Fill system with coolant.
Vehicles without EPC
^ Adjust accelerator cable.
Vehicles with EPC
^ Adapt (match) engine control module to throttle valve control; Refer to Adapt components and functions
Continuation for all models
^ If fault memory has been erased or engine control module was disconnected from permanent positive, respective components must be adapted to engine control module and readiness code generated again.
^ Road test vehicle and interrogate all fault memories:
Refer to Diagnostic tester VAS5051; Guided fault finding; Vehicle system test
Observe the valid safety precautions when performing a road test.
^ Read readiness code.
Vehicles with automatic transmission
^ Adapt transmission control module:
^ Test drive vehicle and interrogate fault memory.