Removing and Installing

ENGINE REMOVAL, NOTES
- Remove engine from front without transmission.
- Always obtain radio security code from the customer before disconnecting the battery Ground strap.
- Ensure ignition is switched OFF before disconnecting battery Ground.
- All cable ties which are opened or cut open when removing engine, must be replaced in the same position when re-installing.
- Remove lock carrier with attachments Removal and Replacement
- Drain engine coolant
- Remove power steering pump with bracket and lay to side; hoses remain connected.
- Disconnect fuel supply and return lines at fuel filter.
- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Pull off/disconnect all electrical connections as necessary from engine and lay to one side.
- Remove starter.
- Disconnect front exhaust pipe from turbocharger.
- Unscrew engine/transmission securing bolts.
- Remove connecting hose between charge air cooler and intake manifold with EGR valve N18, Manifold Absolute Pressure sensor G71 with Intake Air Temperature sensor G72.
- Unscrew upper left and right-hand engine mounting bolts.
Vehicles with A/C
- Observe additional information and removal notes.





- Attach 10-222A engine support bracket as shown.
- Attach 3147 transmission support to bell housing bolt hole (shown in illustration with engine removed).





- Attach lifting tackle 2024 A as follows and lift slightly using VAG 1202 A workshop crane
Pulley end:
2nd hole in hook at position 1
Flywheel end:
2nd hole in hook at position 8

Warning: The hooks and locating pins must be secured with locking pins.

Notes:
^ Positions marked 1 to 4 on bar must be towards pulley end.
^ Holes in hooks are counted up from the hook.

- Lift cut engine forwards.

Notes:
^ Carefully guide engine when lifting, to prevent damaging the bodywork.
^ When working on engine, secure to engine stand using VW 540 engine mounting bracket.

INSTALLING
Installation is carried out in reverse of the removal sequence, note the following when installing:
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing and splines on input shaft with G 000 100 grease (do not grease guide sleeve).
- Check whether centering dowels are installed in cylinder block, install if necessary.
- Align engine mounts stress-free by rocking.
- Allow torque reaction mount to move down onto stop buffer under own weight, tighten bolts to 30 Nm (22 ft. lbs.).
- Install power steering pump
- Install lock carrier with attachments Removal and Replacement
- Install A/C compressor
- Fill with engine coolant
- Electrical connections and routing
- Readiness code, creating





TIGHTENING TORQUES