Engine, Removing

Removal

Special Tools, Testers And Auxiliary Items
- VAG 1921 Spring-clip Pliers
- VAG 1306 Drip tray
- 3277A Installation tool
- 3408 Engine support
- VAG 1383 A Engine/transmission jack
- G 000 100 Grease (for vehicles with manual transmission)
- VAG 1331 Torque wrench (5 to 60 Nm)
- VAG 1332 Torque wrench (40 to 200 Nm)
- Cable tie

- Remove the engine/transmission assembly from below

CAUTION: Obtain the radio anti-theft code before disconnecting the battery ground strap.

- Disconnect battery ground cable
Ignition must be switched OFF

- Always replace all cable ties (in the original position) which were opened or cut while removing the engine

- Drain coolant
- Remove radiator and radiator cooling fan
- Remove ribbed belt





- Detach hose from combi-valve at Air Cleaner upper section -arrow-
- Remove intake manifold complete with intake manifold lower section and Throttle Valve Control Module
- Disconnect power steering lines from right engine support
- Remove power steering pump with bracket and secure to body with wire (hoses remain connected).
- Remove front exhaust pipe.
- Disconnect wiring from transmission, generator and starter and move out of the way
- Disconnect all engine coolant, vacuum and breather hoses

Vehicles With Manual Transmission:
- Pry off line/hose from slave cylinder on transmission.





- Remove transverse support mounting bolts -A- and -B-
- Remove transverse support
- Remove gear change mechanism from transmission.

Vehicles With Automatic Transmission:
- Remove transmission range selector lever cable.

Vehicles With A/C:

CAUTION: Do not open the A/C refrigerant circuit

NOTE: Only break open A/C refrigerant circuit in workshops which have trained personnel and the necessary range of tools and workshop equipment.

To allow engine removal and installation without breaking open the refrigerant circuit:
- Detach refrigerant line retaining clamp(s)
- Remove generator
- Remove A/C compressor
- Secure A/C compressor to vehicle body to relieve any strain or stress to the refrigerant lines and hoses

All Vehicles:
- Remove drive shafts.





- Remove support bracket -1- from cylinder block and pull flange shaft -3- out of transmission shaft -4-
- Remove flange shaft -3- with flange shaft bearing -2-
- Fit 3408 engine support onto VAG 1383 A engine/transmission jack





- Fit 3408 engine support onto cylinder block and tighten mounting nuts -1-
Tighten to: 40 Nm (30 ft lb)

- Remove pendulum support





- Remove right assembly mounting bolt -1-





- Remove left assembly mounting bolts -arrows-
- Carefully lower assembly

CAUTION: Carefully guide the assembly out of the vehicle while lowering, do not allow the assembly to contact and damage the bodywork.

- Mount engine to stand