Removal
Notes on removing
CAUTION: When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
^ Route all types of lines (e.g. for fuel, hydraulic system, coolant, brake fluid, vacuum) as well as the electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.
Note:
^ In subsequent work sequences the battery ground strap must be disconnected. Always check whether a coded radio is installed. Obtain the radio code first if necessary.
^ All cable ties which are opened or cut through when the engine is removed must be replaced in the same position when the engine is installed.
The engine is removed in a downward direction together with the transmission.
- With ignition switched off disconnect battery ground strap.
- Remove oil dipstick.
- Remove engine cover. Pull front of engine cover abruptly upward - arrow A - and then pull forward out of rear securing elements - arrow B -.
- Remove air cleaner housing with intake hose.
- Remove power steering reservoir from battery carrier; do not disconnect/open hoses.
- Tie reservoir up on lock carrier.
- Remove battery and battery bracket.
- Remove lower charge air pipe - 1 -. Remove bolt/screw - 2 - and release connector - arrow - to do this. Carefully cover or close open ends.
- Remove center, left and right side sound insulation.
- Drain coolant.
- Remove rear coolant hose from oil cooler.
- Pull radiator coolant hoses on engine off using hose clamp pliers V.A.G 1921 or pliers for spring-type clips VAS 5024A.
- Remove wiring harness from Generator and move to one side.
- Disconnect all electrical wiring from transmission and starter and move clear.
CAUTION:
^ The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
^ The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure.
^ Wear eye and hand protection when performing any type of repair work on the fuel system!
- Pull fuel supply hose - 1 - and fuel return hose - 2 - off fuel lines on cylinder head.
- Seal lines so that fuel system is not contaminated by dirt etc.
- Remove ribbed belt.
- Remove selector lever cable from transmission.
- Remove all other interconnecting, coolant, vacuum and intake hoses on engine.
- Pull off/disconnect all other electrical connections as necessary from engine and move to one side.
- Remove right side axle shaft and disconnect left side axle shaft at transmission.
- Remove securing clamps for power steering pressure line.
- Remove power steering pump from bracket and move to side. Hoses remain connected.
- Remove bolts - arrows - from pendulum support stated sequence.
Vehicles with air conditioning system
- Note additional information and removal work on models with air conditioning.
- Remove subframe.
- Remove front exhaust pipe.
- Mount engine/trans. support T10012 in engine/transmission jack V.A.G 1383 A.
- Remove bracket for lower coolant hose on cylinder block. Threaded hole is required to secure engine/trans. support T10012.
- Secure engine/trans. support T10012 to cylinder block using M1 0�25/8.8 bolt and tighten to approximately 40 Nm.
- Tighten securing nut of engine/trans. support T10012 on exhaust side by hand.
- Lift engine/transmission jack V.A.G 1383 A slightly.
- Unbolt engine bracket - arrows - (from above) from engine mounting.
Note:
^ To remove securing bolts use double ladder VAS 5085.
- Remove bolts - arrows - of transmission bracket (from above) from transmission mounting.
- Remove bolts - arrows B - of transmission bracket (from above) from transmission mounting.
- Carefully lower engine with transmission.
- When doing this guide power steering pressure line past transmission.
Note:
^ Engine with transmission must be guided carefully when lowering to prevent damage to the bodywork.