Engine, Removing And Installing
Engine, Removing And InstallingSpecial tools, testers and auxiliary items
^ Engine sling 2024 A
^ G 000 100 grease
^ Torque wrench VAG 1331: 5-50 Nm (4-37 ft lb)
^ Torque wrench VAG 1332: 40-200 Nm (30-148 ft lb)
^ Cable ties
Removing
The engine is removed by moving it toward the front together with the transmission.
CAUTION!
Determine correct radio anti-theft coding before disconnecting the battery.
^ Ignition switched off.
- Disconnect battery negative cable (ground strap).
Note:
All tie wraps that are loosened or cut during engine removal must be replaced when the engine is installed.
- Remove air cleaner housing with intake air ducts.
- Loosen power steering reservoir hose clamp.
- Disconnect power steering pressure line clamps from subframe and transmission.
- Remove power steering pump with bracket and lay it to the side; power steering hoses remain connected.
- Drain engine coolant.
- Remove lock carrier (upper radiator support) with attached parts.
- Remove coolant fan and fan shroud.
Vehicles with A/C:
- Refer to ... Vehicles with A/C, additional information on removing and installing.
Vehicles with manual transmission:
- Remove clutch slave cylinder.
- Disconnect gear shift mechanism from transmission.
- Install engine sling 2024 A and lift slightly with shop crane:
Drive belt side:
^ 2nd hole up from hook in cross bar position -1-
Flywheel side:
^ 2nd hole up from hook in cross bar position -7-
Caution!
Always use cotter pins on hooks and pins.
Vehicles with automatic transmission:
- Install engine sling 2024 A and lift slightly with shop crane:
Drive belt side:
^ 4th hole up from hook in cross bar position -1-
Flywheel side:
^ 2nd hole up from hook in cross bar position -6-
CAUTION!
Always use cotter pins on hooks and pins.
Note:
^ The end of the cross bar marked with installation positions 1 through 4 points toward drive belt.
^ Hole numbers in the hook members are counted from the hook end.
All vehicles:
- Disconnect subframe and, on one side, pry bracket from rubber subframe mounting.
- Separate power steering pressure lines from disconnected subframe.
- Lift engine together with transmission out toward the front.
CAUTION!
Lift unit out carefully to avoid damage to body.
For engine repairs, mount engine in engine stand with VW 540 holding fixture.
Installing
Install in reverse order of removal, but note the following:
- Check clutch release bearing for wear, replace if necessary.
- Lightly lubricate clutch release bearing, clutch release guide sleeve and transmission input shaft splines with G 000 100 grease.
- Check whether guide sleeves for centering engine and transmission are in cylinder block; if not, install.
- During installation of engine and transmission be sure to maintain clearance for drive axle shafts.
- When installing engine mounts, be sure that recesses on right rear engine mount bracket and front engine mount engage in guide pins of bonded rubber mounts (arrows).
- Relieve tension on engine mounts by shaking engine.
Tightening torques in table.
- Install clutch slave cylinder.
- Install gear shift mechanism.
- Install power steering pump.
- Install lock carrier with attached parts.
Engines with ribbed drive belt without tensioner:
- Install ribbed drive belt.
All engines:
- Fill engine cooling system coolant.
- Adjust accelerator pedal cable.
- Check electrical connections and routing.
- Check ignition timing and adjust if necessary.
- Carry out idle check.
- Adjust headlights and adjust if necessary.
- If necessary, adjust gear shift linkage cables:
Engine and transmission mount tightening torques:
^ Bolt threads lubricated
Front engine mount
A - 55 Nm (41 ft lb)
B - 55 Nm (41 ft lb)
C - 50 Nm (37 ft lb)
Rear right engine mount
A - 25 Nm (18 ft lb)
B - 50 Nm (37 ft lb)
C - 25 Nm (18 ft lb)
Rear left engine mount for manual transmission
A - 6O Nm (44 ft lb)
B - 25 Nm (18 ft lb)
C - 30 Nm (22 ft lb)
Rear left engine mount for automatic transmission
A - 60 Nm (44 ft lb)
B - 25 Nm (18 ft lb)
C - 30 Nm (22 ft lb)