Engine, Removing And Installing
Engine, removing and installing
Special tools, workshop equipment, test and measuring appliances and auxiliary items required
^ 2024 A Engine sling
^ T10012 Engine bracket
^ VW 313 Support clamp
^ VW 540 Engine / transmission support
^ VAG 1202 A Workshop crane
^ VAG 1306 Drip tray
^ VAG 1331 Torque wrench
5 to 50 Nm (3.7 to 37 ft. lbs.)
^ VAG 1332 Torque wrench
40 to 200 Nm (30 to 148 ft. lbs.)
^ VAG 1383 A Engine/transmission jack
^ VAG 1921 Spring clip pliers
^ VAS 5085 Step ladder
^ G 000 100 grease
(manual transmission, only)
^ Bolt M10 X 25 / 8.8
^ Cable tie
Engine/transmission, removal notes
CAUTION!
Obtain radio anti-theft code from the customer BEFORE disconnecting the battery Ground strap.
Note:
Remove the engine and transmission as an assembly in a downward direction.
- Ensure ignition is switched OFF then disconnect battery Ground strap
- Remove engine cover.
- All cable ties which are opened or cut open to remove the engine, must be replaced in the same position when reinstalling the engine.
- Remove power steering reservoir from battery support but do not loosen hoses.
- Tie reservoir to lock support
- Remove battery and battery bracket
- Separate fuel supply as well as fuel return lines at connection on fuel rail.
WARNING!
Fire Hazard! Do NOT have anything in the area that can ignite Diesel fuel!
WARNING!
The fuel system is under pressure, therefore place a cloth over the connection before the hoses are disconnected.
- Seal lines so fuel system is not contaminated by dirt etc.
- Remove Air Cleaner
Vehicles with manual transmission
- Disconnect Transmission Range selector mechanism from transmission.
- Remove hydraulic clutch slave cylinder:
Vehicles with automatic transmission
- Remove Range selector lever cable from transmission:
=> Automatic transmission 01M
All vehicles
- Remove sound dampener tray:
=> General body repairs
- Drain coolant
=> Refer to Engine coolant, draining.
- Remove ribbed belt
=> Refer to Ribbed belt, removing and installing.
- Remove auxiliary fan on right side of vehicle, if applicable.
- Unscrew mounting clamps for power steering pressure lines
- Remove power steering pump with bracket and lay to one side; hoses remain connected.
=> Running gear
Vehicles with A/C:
- Observe additional information and removal instructions
=> Refer to Vehicles with A/C, additional information and removal instructions.
- Remove inter-connecting, coolant, vacuum and intake hoses on engine.
- Disconnect Secondary Air Injection pump from bracket and remove.
- Disconnect all electric wires from transmission, Generator and starter and move to one side.
- Pull off/disconnect all other electrical connections from engine as necessary and lay to one side.
- Unscrew pendulum support -arrows-.
- Remove right hand inner CV joint protective cover from engine if installed.
- Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission:
- Separate front exhaust pipe from exhaust manifold
=> Refer to Exhaust manifold, front exhaust pipe and catalyst with attachments.
- Install engine bracket 3396 in VAG 1383 A engine/ transmission jack.
- Remove bracket for coolant hose under engine block.
- Mount engine bracket T 100 12 using threaded hole
- Screw on engine bracket T 10012 using fastening nut and screw M10 X 25/8.8 with approx.
^ Tightening torque: 40 Nm (30 ft. lbs.)
- Carefully lift engine and transmission using VAG 1383 A engine/transmission jack .
- Unscrew powertrain mount engine side from the top from the engine mount -arrows-
Note:
Use VAS 5085 to remove mounting bolts.
- Unscrew engine/transmission mount (transmission side) from transmission mount -arrows- from the top.
- Carefully lower engine/transmission assembly.
- When doing this, guide the power steering pressure line past the transmission.
Note:
Carefully guide the engine/transmission assembly while lowering to prevent possible bodywork damage.
Engine to assembly stand, attaching
Note:
To work on the engine, secure it to the VIN 313 assembly stand support clamp using the VIN 540 engine/transmission bracket.
Work sequence
- Take engine/transmission assembly to work bench using VAG 1383A engine sling.
- Set the engine/transmission so the transmission is supported
- Remove lower engine/transmission connecting bolt.
- Press transmission off engine, when doing this, press torque converter out of drive plate.
Vehicles with automatic transmission
- Remove nut from torque converter.
- Clamp-off ATF cooler hoses with -3094- and detach at ATF cooler.
- Attach torque converter to prevent it from falling out.
All vehicles
- Attach 2024A lifting tackle with 2024 A/1 extension as follows and lift out from engine/transmission jack VAG 1383 using workshop crane:
Pulley end:
3rd hole in hook at position 2
Flywheel end:
3rd hole in hook at position 8
WARNING!
Secure all hooks and locating pins with locking pins.
Notes:
^ Ensure that positions marked 1 to 4 on the bar are towards the pulley end.
^ Count the holes in the hooks up from the hook.
- Secure engine to VW 313 support clamp using VW 540 engine/transmission bracket and VW 540/1 kit.
Installation notes
Installation is carried out in the reverse of the removal sequence, during installation note the following:
- Check whether engine/transmission centering dowels are installed in engine block, install if necessary.
- Install intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Vehicles with manual transmission
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
- Install hydraulic clutch slave cylinder
- Install Transmission Range selector mechanism
- If necessary adjust shifting cables:
Vehicles with automatic transmission
- Replace selector cable anchorage locking washer.
- Install Transmission Range selector cable on transmission, adjust if necessary:
All vehicles
- When installing the engine/transmission assembly, ensure sufficient clearance to drive shafts.
- While installing, guide the power steering pressure line past the transmission.
- Align engine/transmission in transverse direction so there is a distance -a- of approx. 10 mm between engine mount -1- and engine support -2-.
- Do not stress the engine and transmission mounting points during installation (aligned parallel to each other)
^ Refer to Tightening torques
- Remove left-hand drive shaft and disconnect right-hand drive shaft at transmission:
- Remove front exhaust pipe
- Adjusting accelerator cable. Refer to Throttle mechanism, servicing.
- Install power steering pump
- Check electrical connections and wire routing:
- Install ribbed belt. Refer to Ribbed belt, removing and installing.
- Install Secondary Air injection pump motor.
- Install sound dampening tray
- Fill system with engine coolant. Refer to Cooling system, draining and filling.
- Make a test drive and check DTC memory
If malfunctions occur
- Display Readiness code
- Match engine Control Module to Throttle Control Module
Vehicles with A/C, additional information and removal instructions
WARNING!
Do NOT open the A/C refrigerant circuit
Note:
To prevent damage to condenser also to the refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
To allow removing and installing the engine without opening the refrigerant circuit:
- Remove retaining clamp(s) from refrigerant lines.
- Remove A/C compressor:
- Attach A/C compressor to body so refrigerant hoses/lines are relieved.
Engine and Transmission Mounts Aligning
CAUTION:
- Engine and transmission must be supported by 10-222A engine support bridge before loosening bolts.
Engine Mount Assembly
a = 14.0 mm (0.55 in)
b = Minimum 10.0 mm 0.040 in)
- Bolt heads 1 must align with edge of mount -c-.
Transmission Mount Assembly
- Edges -a- and -b- must be parallel
Tightening Torques
