Volkswagen Cars 2000-05

Engine 4

Print

Overhaul



Keeping It Maintained

Now that you have just gone through all of that hard work, keep yourself from doing it all over again by thoroughly maintaining it. Not that you may not have maintained it before, heck you could have had one to two hundred thousand miles on it before doing this. However, you may have bought the vehicle used, and the previous owner did not keep up on maintenance. Which is why you just went through all of that hard work. See-



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig.

Now that you have just gone through all of that hard work, keep yourself from doing it all over again by thoroughly maintaining it. Not that you may not have maintained it before, heck you could have had one to two hundred thousand miles on it before doing this. However, you may have bought the vehicle used, and the previous owner did not keep up on maintenance. Which is why you just went through all of that hard work. See-



Click image to see an enlarged view

Fig.

Removal & Installation



If the engine must be removed in order to service it, there are a few preliminary steps which must be executed first.



Clear a place to work.
 
Clean the engine compartment as well as the engine. This will help keep both you and your tools cleaner.
 
Assume the vehicle will be out of order for quite some time.
 
Label all hoses, wires, components, etc.
 
Always plan ahead. Estimate the amount of needed time, tools, etc. Don't get cut short. This is a lengthy task.
 

The engine and transmission are removed as a unit and then disassembled. The removal of some front body work may be required.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. The engine and transaxle are removed from the vehicle as an assembly.
  4.  
  5. Remove or disconnect:

    Battery cables and battery.
     
    Fuel pressure. Open the fuel filler cap to relieve tank pressure, then loosen the fuel filter fitting. Be sure to take the appropriate fire safety precautions.
     
    Engine top cover
     
    Right driveshaft
     
    Disconnect left driveshaft at transmission
     
    Radiator hoses
     
    4 bolts and front engine support
     
    Air cleaner
     
    Engine undercover
     
    Drive belt
     
    A/C compressor and wire aside
     
    Automatic transmission range selector lever
     
    All vacuum and breather hoses from engine
     
    Transmission, alternator and starter wiring
     
    Intake air pipes between charge air cooler and turbocharger
     
    Power steering pump
     
    Power steering hose mounting clamps
     
    Right CV joint cover from right side
     
    Front exhaust pipe and catalytic converter
     

  6.  


CAUTION
On some models, special tools are required for removing and installing the exhaust pipe-to-manifold spring clamps: VW3140/1 and /2 or equivalent. This is a set of different sized wedges for spreading the spring clamps in steps. The installed spring clamp has considerable tension and could cause damage or injury if not properly removed. Clamps with wedges installed are also under high tension and should be handled carefully.



Fuel inlet and outlet lines from the injection pump and plug the holes to keep the pump clean. Note the outlet fitting has a special orifice.
 
On turbocharged engines, exhaust pipe and the oil lines from the turbocharger and cap the oil line fittings on the turbocharger.
 
Speedometer cable from the transaxle and plug the hole in the case.
 

  1. Attach an engine sling tool VW-2024A or equivalent, to the engine and attach the sling to a suitable lifting device.
  2.  
  3. Remove or disconnect:

    Engine mount from engine bracket
     
    Engine transmission mount from transmission bracket
     

  4.  
  5. With all mounts unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side. Then, carefully lower the assembly out of the vehicle.
  6.  

To install:

  1. Carefully install the engine/transaxle assembly and be sure all mounts are securely bolted to the engine/transaxle. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.
  2.  
  3. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts.Bolts, starting at the rear and working forward: 30 ft. lbs. (40 Nm) for 10mm bolts or 44 ft. lbs. (60 Nm) for 12mm bolts.
  4.  
  5. Install or connect:

    Starter. Bolts: 50 ft. lbs. (65 Nm).
     
    Halfshafts to the flanges. Bolts: 30 ft. lbs. (40 Nm).
     
    Exhaust pipe and use new self-locking nuts to secure the flange. Nuts: 18 ft. lbs. (25 Nm). If equipped with spring clamps, the clamps can be used again.
     
    Shift linkage and the clutch slave cylinder. Make any necessary adjustments.
     
    Speedometer cable
     
    On turbocharged engines, exhaust pipe and the oil lines to the turbocharger
     
    Fuel inlet and outlet lines to the injection pump
     
    4 bolts and front engine support
     
    Right CV joint cover to right side
     
    Power steering hose mounting clamps
     
    Power steering pump
     
    Intake air pipes between charge air cooler and turbocharger
     
    Transmission, alternator and starter wiring
     
    All vacuum and breather hoses to engine
     
    Automatic transmission range selector lever
     
    A/C compressor
     
    Drive belt
     
    Engine undercover
     
    Air cleaner
     

  6.  
  7. Fill the engine with coolant and oil. Start the engine and check for leaks.
  8.  

Removing an engine from a vehicle requires the disconnection or removal of many components and the removal of many fasteners. If possible, before starting the removal procedure, clean the engine and engine compartment thoroughly. Lubricate any rusted or corroded fasteners with a penetrating lubricant to ease disassembly.

Prepare and organize your work area before beginning any component removal. Have drain pans and sealable containers available to catch any drained fluids or residual fluid spills. Have several boxes set aside for larger components, and containers for any removed hardware and brackets. Clear plastic sealable freezer bags work well for organizing removed hardware, and can be written on for future reference using a permanent felt tipped marker.

Have a roll of masking tap and a pencil handy to label removed or disconnected items such as the wiring, hoses, fuel lines and brackets. If necessary, make small notes on masking tape and attach them to the areas of the engine compartment where components, retainers, cable ties or related items were removed or routed. This ensures proper mounting of removed components and the correct routing of any disconnected harnesses, cables or brackets.

Have a small notebook handy to take notes and keep track of parts or supplies that might be needed during disassembly or assembly. Any fasteners that have become rounded off or have become corroded should be replaced. During removal, inspect the hoses, wires, cables, and fluid lines and replace them if they show signs of deterioration or damage. Once the engine, and if necessary, the transaxle are removed, accessibility is greatly increased and replacement of the related components is far easier and less time consuming.

Protect the vehicle's painted surfaces using suitable fender covers or their equivalent. If the hood is to be removed, protect the rear corners with masking tape on both the hood and the body of the vehicle. Tape cardboard over the corners of the hood before removal. This will allow the hood to be stored upright without damage. If necessary, a thick protective masking tape is available from an automotive paint supply vendor.

During assembly, make sure all hoses, wires, cables, and fluid lines are installed such that they are not resting on sharp edges or subjected to areas of excessive heat. If routing requires they be near any moving components such as mechanical linkages, belts or pulleys, be sure to secure them with suitable cable ties, retainers or the original brackets supplied by the manufacturer.

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as 'disconnect the exhaust system' or 'remove the radiator. In most instances, a detailed removal procedure can be found elsewhere in this product.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in clear plastic sealable freezer bags, muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside. Take care to not kink or damage the high pressure hoses.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on a suitable engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined herein.
 


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do NOT allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.


CAUTION
NEVER open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

1.8L Engine

NOTE
To allow clearance for removal of the engine assembly, the front bumper and the hood lock carrier assembly must be removed from the front of the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Obtain the radio security code.
  4.  
  5. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  6.  
  7. Position the wipers to the vertical position.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Disconnect the negative battery cable.
  12.  
  13. Remove the lower engine slash shield.
  14.  
  15. Drain the engine coolant from the radiator into a suitable container, then remove the water pump housing drain plug, drain the remaining coolant and reinstall the drain plug using a new sealing washer.
  16.  
  17. Remove the front bumper. For additional information, please refer to the following topic(s): Body And Trim, Front Bumper.
  18.  
  19. Remove the front hood lock carrier assembly. For additional information, please refer to the following topic(s): Body And Trim, Hood Lock Carrier.
  20.  
  21. Disconnect the air conditioning low-pressure switch.
  22.  
  23. Detach the green harness connector from the air conditioning compressor magnetic clutch.
  24.  
  25. Remove the engine covers.
  26.  
  27. Detach the wiring harness connectors for the wastegate bypass regulator valve, the Evaporative Emissions (EVAP) canister purge regulator valve, the power output stage, and the Mass Air Flow (MAF) sensor.
  28.  
  29. Detach the Engine Coolant Level (ECL) warning switch.
  30.  
  31. Disconnect the coolant hoses at the expansion tank, then remove the tank and position it aside.
  32.  
  33. If equipped with cruise control, detach the actuating rod from the throttle valve control module, then remove the vacuum hose from the vacuum unit.
  34.  
  35. Detach the accelerator pedal cable from the throttle valve control module.
  36.  
  37. Remove the hose for the Leak Detection Pump (LDP).
  38.  
  39. Disconnect the fuel supply and return lines.
  40.  
  41. Disconnect the brake booster vacuum hose.
  42.  
  43. Remove the vacuum hose for the Evaporative Emissions (EVAP) canister purge regulator valve.
  44.  
  45. Uncover the E-box.
  46.  
  47. Unclip the Motronic Engine Control Module (ECM) retaining bracket.
  48.  
  49. Detach the wiring harness to the ECM.
  50.  
  51. If equipped with an automatic transaxle, detach the kickdown switch connector.
  52.  
  53. Detach the heated oxygen (O 2 S) sensor wiring harness.
  54.  
  55. Detach the ground connection at the plenum chamber.
  56.  
  57. Disconnect the heater hoses from the heater core.
  58.  
  59. Detach the Vehicle Speed Sensor (VSS) from the transaxle and position it aside.
  60.  
  61. If equipped with a manual transaxle, detach the backup light switch connector from the transaxle.
  62.  
  63. Remove the engine driven cooling fan.
  64.  
  65. Remove the accessory drive belts.
  66.  
  67. Unbolt the air conditioning compressor from the mounting bracket and position it aside and properly secure.
  68.  
  69. Disconnect the power steering pump and position it aside leaving the hoses attached.
  70.  


NOTE
The flexpipe at the front exhaust pipe must not be bent more than 10 degrees. Otherwise it may be damaged.

  1. Disconnect the catalytic converter from the turbocharger.
  2.  
  3. Remove the starter, and the ground strap at the right engine mount.
  4.  
  5. If equipped with an automatic transaxle, remove the 3 torque converter-to-driveplate mounting bolts through the opening left by the starter.
  6.  
  7. Loosen the upper nuts for the left and right engine mounts.
  8.  
  9. Place matchmarks on the threaded bolt and centering sleeves at the bottom of the left and right engine mounts, and then remove the mounting nuts.
  10.  
  11. Remove the lower engine-to-transaxle mounting bolts.
  12.  
  13. If equipped with an automatic transaxle, remove the cooler line bracket form the left side of the engine.
  14.  
  15. Remove the upper nuts from the engine mounts.
  16.  
  17. Position an engine support bridge tool No. 10-222A, or equivalent, to the bolted flanges of the fenders with the spindle facing forward.
  18.  
  19. Attach the support adapter tool No. 3147, or equivalent, to the bolt hole above the starter mounting area in the transaxle bell housing.
  20.  
  21. Connect the engine support adapter tool No. 3147 to the engine support bridge tool No. 10-222A using adapter tool No. 2024A/1 and extension tool No. 2024A/2, or their equivalents, and support the transaxle.
  22.  
  23. Attach a suitable engine sling between the engine and the hoist.
  24.  
  25. Remove the upper engine-to-transaxle mounting bolts.
  26.  
  27. Separate the engine from the transaxle, then slowly lift the engine up and out the front of the engine compartment.
  28.  
  29. If equipped with an automatic transaxle, secure the torque converter to prevent it from falling out.
  30.  



Click image to see an enlarged view

Fig. Bumper mounting fastener (1), energy absorbing strut fasteners (2), strut assembly (3), saddle (4), bumper cover (5), spoiler (6) and liner fastener (7)-A4 & 1998-00 Passat models



Click image to see an enlarged view

Fig. Exploded view of the hood lock carrier assembly-A4 & 1998-00 Passat models



Click image to see an enlarged view

Fig. The engine support bridge and hook used to support the weight of the transmission for engine removal or weight of the engine for transmission removal-shown supporting the transmission with the engine removed



Click image to see an enlarged view

Fig. Be sure to attach the engine sling properly

To install:


NOTE
Be sure that the centering sleeves for the engine-to-transaxle are correctly installed in the cylinder block.

  1. Verify that the intermediate plate is over the centering sleeves.
  2.  
  3. Install the engine into the vehicle.
  4.  
  5. Install the upper engine-to-transaxle mounting bolts.
  6.  
  7. Lower the engine into position, then remove the engine sling and hoist.
  8.  
  9. Remove the transaxle support apparatus from the vehicle.
  10.  
  11. Install the engine mounting fasteners without any tension or pre-load.
  12.  
  13. If equipped with an automatic transaxle, install the transmission cooler line bracket to the left side of the engine.
  14.  
  15. Install the lower engine-to-transaxle mounting bolts, and tighten the mounting bolts as follows:
  16.  


    M12 bolts: 48 ft. lbs. (65 Nm)
     
    M10 bolts: 33 ft. lbs. (45 Nm)
     

  17. Tighten the engine mounting fasteners to 18 ft. lbs. (25 Nm).
  18.  
  19. If equipped with an automatic transaxle, install the driveplate-to-torque converter mounting bolts through the starter opening and tighten to 63 ft. lbs. (85 Nm).
  20.  
  21. Install the starter and attach the ground strap to the right engine mount.
  22.  
  23. Attach the catalytic converter to the turbocharger and tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  24.  
  25. Install the power steering pump, the air conditioning compressor, and the engine cooling fan, then the accessory drive belts.
  26.  
  27. If equipped with a manual transaxle, connect the backup light switch to the transaxle.
  28.  
  29. connect the VSS sensor to the transaxle.
  30.  
  31. Connect the heater hoses to the heater core.
  32.  
  33. Attach the ground connection at the plenum chamber.
  34.  
  35. Attach the heated O 2 S sensor wiring harness.
  36.  
  37. If equipped with an automatic transaxle, attach the kickdown switch connector.
  38.  
  39. Connect the wiring harness to the ECM.
  40.  
  41. Install the ECM retaining bracket and cover the E-box.
  42.  
  43. Connect the vacuum hose for the EVAP canister purge regulator valve.
  44.  
  45. Connect the fuel supply and return lines.
  46.  
  47. Connect the brake booster vacuum hose.
  48.  
  49. The completion of the installation procedure is the reverse of the removal, keeping in mind the following items.
  50.  


    If equipped with an automatic transaxle, check the fluid level and top off as necessary.
     
    Fill the engine with coolant and bleed as necessary
     
    Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function
     
    Check the oil level before starting the engine and top off as necessary
     

  51. Connect the negative battery cable.
  52.  
  53. Enter the radio security code.
  54.  
  55. Set the clock to the correct time.
  56.  


NOTE
Diagnostic Trouble Codes (DTCs) are stored when harness connectors are detached.

  1. Clear the fault codes.
  2.  
  3. Adjust the headlights if necessary.
  4.  

2.0L Engine

The engine is removed along with the transaxle. The front grill, radiator and upper radiator support/hood latch support must be removed. Removal of the hood is optional, however the ease of removal affords additional working space.


NOTE
It is recommended that the hood be removed, to allow easier access to all areas of the engine, although it is not required.

Always label all lines and hoses so they can be reconnected correctly.

  1. Disconnect the battery cables and remove the battery.
  2.  
  3. If your vehicle is equipped with an anti-theft system, know your deactivation code before you remove any of the battery cables.
  4.  
  5. Relieve the fuel system pressure as follows:
  6.  
    1. Remove the fuel filler cap to relieve tank pressure.
    2.  
    3. On 9A engines, loosen the cold start injector line to relieve the fuel system pressure on CIS-E fuel injection systems.
    4.  
    5. On ABA engines, loosen the pressure test port fitting at the end of the fuel rail that supplies the injectors.
    6.  

  7. The air intake duct between the air cleaner and the throttle body must also be removed.
  8.  
  9. Detach the accelerator cable from the throttle and remove the cable housing from the bracket.
  10.  
  11. Set the heater temperature control to maximum.
  12.  
  13. Remove the radiator cap and place a pan under the thermostat housing and remove the thermostat flange to drain the coolant.
  14.  
  15. Remove the air conditioner compressor and the condenser without disconnecting the pressure lines and secure them out of the way.
  16.  
  17. Remove the upper radiator hose and disconnect the wiring from the radiator fan motor and switches. Remove the upper mounting brackets and lift out the radiator and fan as an assembly.
  18.  
  19. Remove the front upper radiator support/hood latch support as follows:
  20.  
    1. Detach the headlight electrical connectors and the hood release cable from the hood latch assembly.
    2.  
    3. Remove the lower valance and the front grille, and front apron.
    4.  

  21. Disconnect all electrical connections and vacuum lines, carefully labeling each one.
  22.  


NOTE
Don't forget ground connections that are screwed to the body.

  1. Remove the power steering pump and reservoir as a unit without disconnecting the fluid lines.
  2.  
  3. On 9A engines, the entire fuel injection system can be removed as a unit as follows:
  4.  
    1. Without disconnecting the lines, carefully pry the injectors from their holes and protect them with caps.
    2.  



NOTE
A little silicone spray can greatly ease the removal of the injectors. If necessary using a locking needle nose pliers clamped onto the fuel line nut, then carefully pry on the tip of the pliers using a suitable prytool.

  1. As the cold start injector is removed, tape all the injector lines together and set them aside.
  2.  
  3. Detach the wiring and the fuel supply line from the fuel distributor. Plug the fuel inlet to keep dirt out of the fuel distributor.
  4.  
  5. Disconnect the fuel return line from the pressure regulator.
  6.  
  7. Remove the bolts or clips required to remove the air filter and lift the air flow sensor along with the fuel system out of the vehicle.
  8.  

  1. On ABA engines, disconnect the fuel supply line from the pressure regulator and the fuel return line from the fuel rail. Disconnect the plug on the end of the injector wiring harness.
  2.  
  3. If equipped with an automatic transaxle,
  4.  
    1. Place the selector lever in the 'PARK' position.
    2.  
    3. Disconnect the shifter cable at the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
    4.  

  5. On vehicles with a manual transaxle,
  6.  
    1. Remove the 2 rods with the plastic socket ends and unbolt the remaining linkage from the transaxle case as required.
    2.  
    3. Disconnect the clutch cable, lift it from the case and set it aside.
    4.  

  7. Detach the wiring from the starter and the back-up light switch and disconnect the ground cable from the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
  8.  
  9. Raise and safely support the vehicle on jack stands.
  10.  
  11. If the engine or transaxle are to be disassembled, drain the lubricant into a suitable container and if equipped, install the drain plugs using a new sealing washer.
  12.  


WARNING
Make sure to check all fluid levels and top off as necessary upon assembly.

  1. Spray the centers of the halfshaft mounting fasteners with a suitable penetrating lubricant and thoroughly clean them using a small pick or wire brush if necessary.
  2.  
  3. Using the appropriate 8mm hex tool or spline tool, make sure the tool is fully seated into the fastener and loosen them from the transaxle output flanges.
  4.  
  5. Once removed, support the axles level with the ground using mechanics wire, or if the vehicle will need to be rolled, make a sling by carefully cutting a 2 inch (50 mm) wide cross section from a typical anti-freeze container. Place the sling over the axle and support the sling with mechanic's wire tied to the body. Spray a light coating of a penetrating lubricant to the surface where the slings contact the axle. Make sure to position the slings such that they Do NOT contact the CV boots.
  6.  


WARNING
Do NOT let the halfshafts hang by the outer CV joint or the joint may fall apart.

  1. Unbolt the front exhaust down pipe from the exhaust manifold.
  2.  
  3. Attach a suitable chain sling to the lifting eyes.
  4.  


NOTE
On 9A engines, a rigid sling must be used. Remove the idle stabilizer valve and upper intake manifold and attach a proper engine sling, Tool No. VW-2024A, or equivalent, to the engine.

  1. Check to make sure everything is disconnected, then unbolt the mounts. Remove the starter first and the front mount with it.
  2.  
  3. Once all of the mounts have been unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side.
  4.  
  5. Carefully lift the engine and transaxle assembly upward and making sure all brackets, hoses, lines and electrical connectors have been removed or disconnected as necessary and remove the driveline assembly from the vehicle.
  6.  
  7. Lower the driveline assembly and support the engine using suitable blocks of wood and place a suitable floor jack under the transaxle, and support the transaxle.
  8.  
  9. On vehicles equipped with an automatic transaxle, remove the torque converter to flex plate fasteners, then slide the torque converter back toward the transaxle slightly.
  10.  
  11. Starting from the bottom and working upward, carefully loosen and remove all the fasteners securing the transaxle assembly to the engine. Make sure to keep both mating surfaces parallel with one another and remove the transaxle assembly from the engine. For additional information, please refer to the following topic(s): Drivetrain, Manual Transaxle, Automatic Transaxle.
  12.  

To install:

  1. Install the transaxle onto the engine assembly. Make sure to keep both mating surfaces parallel with one another when assembling the transaxle assembly to the engine. Start from the top and work downward, and carefully tighten all the fasteners securing the transaxle assembly to the engine. For additional information, please refer to the following topic(s): Drivetrain, Manual Transaxle, Automatic Transaxle.
  2.  
  3. On vehicles with an automatic transaxle, make sure to fasten the torque converter to the flexplate.
  4.  
  5. Make sure all mount brackets are securely bolted to the engine/transaxle. Fit the assembly into the engine bay making sure there is adequate clearance between the axles, and install the mounts, starting at the rear. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.
  6.  
  7. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at the rear and working forward. Torque to 33 ft. lbs. (41 Nm) for 10mm bolts or 54 ft. lbs. (73 Nm) for 12mm bolts.
  8.  
  9. Install the starter and torque the bolts to 33 ft. lbs. (45 Nm).
  10.  
  11. Attach the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  12.  
  13. Connect the exhaust pipe. On 9A engines, use new self-locking nuts to secure the flange and torque the nuts to 30 ft. lbs. (40 Nm).
  14.  
  15. As necessary, attach the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  16.  
  17. Install the fuel system components and connect the lines. Lubricate all fuel line O-rings with a light coating of fresh engine oil.
  18.  
  19. Install the front upper radiator/hood lock support and connect the wiring.
  20.  
  21. If equipped, install the air conditioning compressor and/or power steering pump, then install and adjust the drive belts.
  22.  
  23. Install the radiator, fan and heater hoses.
  24.  
  25. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  26.  
  27. Connect all of the remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  28.  
  29. Fill the cooling system using the recommended coolant, distilled water and mixture ratio using. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  30.  
  31. Check and top off all fluid levels as necessary. For additional information, please refer to the following topic(s): General Information And Maintenance, Fluids And Lubricants.
  32.  
  33. Check the adjustment of the accelerator cable and adjust as necessary.
  34.  
  35. Start the engine, check for fluid leaks, test drive and check for normal operation.
  36.  

2.8L Bdf Engine

NOTE
Tag all hoses and wiring during removal, to use as reference during reassembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The engine and transaxle are lifted from the vehicle as an assembly.

  2.  
  3. Remove or disconnect:

    Battery cables and battery.
     
    Fuel pressure, by opening the fuel filler cap, loosening the fuel filter fitting. Be sure to take the appropriate fire safety precautions.
     
    Front engine cover
     
    Ignition coil connectors
     
    Air cleaner and intake hose
     
    Throttle valve vacuum hose
     
    Fuel return and supply lines
     
    Engine undercovers
     
    Radiator grille
     

  4.  
  5. Lock the carrier into service position as follows:
    1. Remove the front bumper.
    2.  
    3. Tag and remove any wiring or connector that would inhibit locking the carrier.
    4.  
    5. Disconnect Bowden cable from lock.
    6.  
    7. Remove the 2 No. 2 bolts.
    8.  
    9. Remove the 4 No. 7 bolts.
    10.  
    11. Remove the 4 No. 8 bolts.
    12.  
    13. Install Guide Rods 3411.
    14.  
    15. Remove the remaining bolts and pull the lock carrier out to the stop.
    16.  
    17. To secure the lock carrier, install the appropriate M6 bolts into the rear of the lock carrier and fender.

      Click image to see an enlarged view

      Fig. Moving the lock carrier into the service position-2.8L (BDF) engine GTI and Jetta

    18.  

  6.  
  7. Remove or disconnect:

    Cylinder head cover.
     
    Intake manifold.
     
    Accessory drive belt.
     
    Power steering pump and secure it to the body. Do not disconnect the hydraulic lines.
     
    Air conditioning compressor and secure it to the body.
     
    On manual transaxle shift linkage, 2 rods with the plastic socket ends and remaining linkage from the case as required. Disconnect the clutch cable, lift it out of the case and set it aside.
     
    Clutch hydraulic line and cap opening.
     
    With an automatic transaxle, selector cable at the transaxle, with selector lever in P (park).
     
    All remaining vacuum hoses and electrical connectors.
     
    Drain coolant.
     
    Coolant hoses from radiator and engine.
     
    Halfshafts from the flanges and hang them from the body with wire.
     
    Pendulum support under vehicle.
     
    Exhaust pipe from the manifold.
     
    Alternator and bracket.
     
    Air injection pump bracket from block and oil pan.
     

  8.  
  9. Install engine bracket 3395 to cylinder block and tighten securing nuts.
  10.  
  11. Install engine transmission jack to bracket tool 3395.
  12.  
  13. With all mounts unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side. Then, carefully lift the assembly out of the vehicle.
  14.  

To install:


NOTE
Be sure that the centering sleeves for the engine-to-transaxle are correctly installed in the cylinder block.

  1. Carefully install the engine/transaxle assembly and be sure all mounts are securely bolted to the engine/transaxle. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.
  2.  
  3. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Tighten all mounting bolts, starting at the rear and working forward. Tighten to 11 ft. lbs. (15 Nm) for 7mm bolts, tighten to 18 ft. lbs. (25 Nm) for 8mm bolts, tighten to 33 ft. lbs. (41 Nm) for 10mm bolts or 44 ft. lbs. (60 Nm) for 12mm bolts.
  4.  
  5. Install or connect:

    Alternator and bracket. Bolts: 18 ft. lbs. (25 Nm).
     
    Exhaust pipe and use new self-locking nuts to secure the flange. Nuts: 30 ft. lbs. (40 Nm). If equipped with spring clamps, the clamps can be used again.
     
    Pendulum support.
     
    Halfshafts to the flanges. Bolts: 33 ft. lbs. (45 Nm).
     
    Shift linkage and the clutch cable, if equipped.
     
    Clutch hydraulic line. Bleed clutch when finished.
     
    Manual transaxle linkage rods, or automatic transaxle selector cable.
     
    Power steering pump. Bolts: 18 ft. lbs. (25 Nm).
     
    Intake manifold. Bolts: 10 ft. lbs. (13 Nm).
     
    Cylinder head cover. Bolts 71 inch lbs. (8 Nm).
     
    Air cleaner and intake hose.
     
    Battery and tray.
     
    Accessory drive belt.
     
    All electrical connectors and vacuum lines.
     

  6.  
  7. The completion of the installation procedure is the reverse of the removal.
  8.  
  9. If equipped with an automatic transaxle, check the ATF level
  10.  
  11. Fill the engine with coolant
  12.  
  13. Fully close all power windows, operate all window switches for at least 1 second in the close direction to activate the one-touch opening/closing function
  14.  
  15. Connect the negative battery cable.
    NOTE
    DTCs are stored when harness connectors are detached.

  16.  
  17. Read the DTCs and clear the fault codes.
  18.  

2.8L Engine

NOTE
The engine is removed without the transaxle, through the top of the engine compartment. On all A4 & 1998-00 Passat models the front bumper and the front lock carrier assembly must be removed.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine undercover, and then the soundproofing material holder from the engine mount.
  4.  
  5. Drain the engine coolant into a suitable container.
  6.  
  7. Remove the front bumper and hood lock carrier assembly, placing the A/C condenser aside without disconnecting the high-pressure hoses. For additional information, please refer to the following topic(s): Body And Trim, Front Bumper, Hood Lock Carrier.
  8.  
  9. Remove the stabilizer brace from the right rear of the engine compartment.
  10.  
  11. Remove the wiper arms and water deflector trim.
  12.  
  13. Properly relieve the fuel system pressure.
  14.  
  15. Label and detach all hoses, wiring harnesses, lines and cables as necessary for engine removal.
  16.  
  17. Remove the accessory drive belt guard, then the belt.
  18.  
  19. Detach the front engine mount at the crossmember.
  20.  
  21. Disconnect and plug the hydraulic lines that route above the cylinder head covers from the power steering pump.
  22.  
  23. Detach the ground strap from the right side engine support.
  24.  
  25. Remove the air intake for the alternator.
  26.  
  27. Remove the alternator and place aside and secure.
  28.  
  29. Remove the engine cooling fan. Cover and protect the right front fender, then disconnect the air conditioning condenser mounting brackets and with the hoses attached, move the condenser to the right front wheel area and secure.
  30.  
  31. Unbolt the air conditioning compressor and tie it aside leaving the hoses attached.
  32.  
  33. Disconnect the exhaust system from the manifolds.
  34.  
  35. Disconnect the front exhaust pipes with the catalytic converters.
  36.  
  37. Unbolt the starter and pull out rearward, leaving the wires attached, then secure the starter to one side.
  38.  
  39. Remove the oil filter, then loosen and remove the oil cooler from under the filter.
  40.  
  41. If equipped with automatic transmission, remove the flexplate-to-torque converter attaching bolts through the starter opening.
  42.  
  43. Remove the engine-to-transmission mounting bolts.
  44.  
  45. Position an engine support bridge tool No. 10-222A, or equivalent, to the bolted flanges of the fenders with the spindle facing forward.
  46.  
  47. Attach the support adapter tool No. 3147, or equivalent, to the bolt hole above the starter mounting area in the transaxle bell housing.
  48.  
  49. Connect the engine support adapter tool No. 3147 to the engine support bridge tool No. 10-222A using adapter tool No. 2024A/1 and extension tool No. 2024A/2, or their equivalents, and support the transaxle.
  50.  
  51. Attach a suitable engine sling tool No. 2024A, or equivalent, to the right rear and left front of the engine.
  52.  
  53. Attach an engine hoist to the sling.
  54.  
  55. Lift the engine slightly.
  56.  
  57. Check that all hoses, wires, cables and mounts have been disconnected and carefully lift the engine in conjunction with the transmission to clear the right engine mount.
  58.  
  59. Carefully pull the engine forward until it is separated from the transmission.
  60.  
  61. After the engine has been separated from the transmission, lift the engine up and out of the vehicle.
  62.  

To install:


NOTE
Before installing the engine, on manual transmissions, inspect the clutch components for wear or damage, and replace if necessary. short blocks are supplied without the sleeve in the crankshaft. For vehicles equipped with an automatic transmission, tap the sleeve into place before installing the flexplate, if equipped with a manual transmission, install a pilot bearing. Lightly lube the clutch release bearing and the transmission input shaft with G 000 100, or equivalent, grease. Check that the alignment sleeves for centering the engine and transmission are properly installed in the engine block. Install sleeves if missing or damaged. Replace all self-locking nuts.

  1. Slowly lower the engine into the vehicle.
  2.  
  3. Position the starter, and then engage the engine to the transmission.
  4.  
  5. Simultaneously lower the engine and transmission into position.
  6.  


NOTE
Install the engine mounts without any pre-load and without tension. Ensure proper alignment by rocking the engine before tightening the engine mounts.

  1. Install the engine mounts and tighten the bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. The completion of the installation is the reverse of the removal procedure. Note the following items.
  4.  


    Tighten the flexplate-to-torque converter mounting bolts to 63 ft. lbs. (85 Nm)
     
    Tighten the engine-to-transmission attaching bolts to 18 ft. lbs. (24 Nm) for the M8 bolts, 33 ft. lbs. (45 Nm) for the M10 bolts, and 48 ft. lbs. (65 Nm) for the M12 bolts
     
    If equipped with an automatic transaxle, check the fluid level and top off as necessary.
     
    Fill the engine with coolant and bleed as necessary
     
    Fully close all power windows to stop, operate all window switches for at least 1 second in the close direction to activate the one touch opening/closing function
     
    Check the oil level before starting the engine and top off as necessary
     

  5. Connect the negative battery cable.
  6.  
  7. Enter the radio security code.
  8.  
  9. Set the clock to the correct time.
  10.  


NOTE
Diagnostic Trouble Codes (DTCs) are stored when harness connectors are detached.

  1. Clear the fault codes.
  2.  
  3. Adjust the headlights if necessary.
  4.  

Diesel Engines

The engine and transmission are lifted from the vehicle as an assembly and separated afterwards. Some of the front body work must be removed but removing the hood is not necessary unless it interferes with the lifting equipment. Some components can be removed without disconnecting hydraulic or coolant hoses. Cover the front fenders so components can be hung over them. Before beginning the job, make sure you have some way of labeling the wires, lines and hoses so they can be reconnected correctly.

  1. Remove the battery.
  2.  
  3. Turn the heater temperature control to maximum. Remove the radiator cap and the radiator hose at the thermostat housing and drain the cooling system. Remove the thermostat flange.
  4.  
  5. Disconnect the wiring from the radiator fan motor and the thermo-switch. Remove the upper radiator mounting brackets and lift the radiator and fan out of the vehicle.
  6.  
  7. Remove the fuel filter and base. Cap the fuel line connections to prevent leakage.
  8.  
  9. Detach the brake booster hose from the vacuum pump.
  10.  
  11. Remove the alternator wiring and then the unit.
  12.  
  13. Detach the wiring to the fuel shut-off solenoid, the glow plugs, the oil pressure switch and the coolant temperature sensor.
  14.  
  15. Disconnect the heater and the expansion tank hoses.
  16.  
  17. At the injection pump, disconnect the accelerator cable and the cold start cable.
  18.  
  19. Disconnect the fuel supply and the return lines from the injection pump. Plug the openings in the pump and cap the ends of the lines to prevent the entry of dirt into the system.
  20.  
  21. If equipped with air conditioning, the injection pump must be removed to remove the compressor. See Section 5 for instructions on removing the pump. To remove the compressor:

    Remove the air conditioning belt tensioner, water pump pulley and drive belt.
     
    Disconnect the wiring from the compressor and the pressure switches.
     
    Remove the condenser and compressor together without disconnecting the coolant hoses.
     
    Secure the compressor and condenser out of the way. Do not let them hang by the coolant hoses.
     

  22.  
  23. Remove the front body section as described:

    Disconnect the headlight electrical connectors and the hood release cable from the hood latch assembly.
     
    Remove the lower valance and the front grille.
     
    Remove the front apron
     

  24.  
  25. If equipped with power steering, remove the pump without disconnecting the hydraulic hoses. Secure the pump out of the way, do not let it hang by the hoses.
  26.  
  27. Disconnect the wiring from the starter, back-up light switch and the transaxle mount ground wire.
  28.  
  29. If equipped with a manual transaxle, disconnect the clutch cable and shift linkage.
  30.  
  31. On vehicles with an automatic transaxle, place the selector lever in the P position and disconnect the shifter cable at the transaxle.
  32.  
  33. Remove the speedometer cable from the transaxle and plug the hole in the case.
  34.  
  35. If not already done, raise and safely support the vehicle on jack stands.
  36.  
  37. Unbolt the halfshafts from the flanges and hang them from the body with wire.
  38.  


WARNING
DO NOT let the halfshafts hang by the outer CV joint or the joint may fall apart.


NOTE
The exhaust pipe is secured to the manifold with spring clamps. Use the proper tools and procedures for removal and installation. The springs are under heavy tension and can cause serious injury if mishandled.

  1. To remove the exhaust pipe spring clamps:

    Push the pipe to one side to expand the opposite clamp. Insert a wedge into the expanded clamp.
     
    Push the pipe to the other side and insert a wedge into the clamp.
     
    Push the pipe the other way again to expand the clamp further. It should be possible to grab the wedge with locking pliers and pry the clamp off the pipe flange.
     

  2.  
  3. Leave the wedges in the clamps and put them in a box so they won't be disturbed and fly apart.
  4.  
  5. Check carefully to make sure all necessary wiring, hoses and linkages have been disconnected. Attach a chain yoke and a hoist to the engine, then lift it slightly.
  6.  
  7. Unbolt the engine mounts, tilt the assembly down at the transaxle side and carefully lift the engine and transaxle out. See Section 7 for information on separating the engine and transaxle.
  8.  

To install:


NOTE
See Section 7 for information on assembling the engine and transaxle. Make sure all mount brackets are securely bolted to the engine/transaxle. Fit the assembly into the engine bay and install the mounts, starting at the rear. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.

  1. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at the rear and working forward. Torque to 33 ft. lbs. (41 Nm) for 10mm bolts or 54 ft. lbs. (73 Nm) for 12mm bolts.
  2.  
  3. Install the starter and torque the bolts to 33 ft. lbs. (45 Nm).
  4.  
  5. Connect the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Connect the exhaust pipe.
  8.  
  9. Connect the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  10.  
  11. Install the front apron and connect the wiring.
  12.  
  13. Install the air conditioner compressor and condenser.
  14.  
  15. Install the fuel injection pump as described in Section 5.
  16.  
  17. Install the power steering pump. Install and adjust all accessory drive belts.
  18.  
  19. Install the radiator, fan and heater hoses. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  20.  
  21. Install the remaining components and connect all remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  22.  
  23. Fill and bleed the cooling system. Check the adjustment of the accelerator cable.
  24.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. The engine and transaxle are removed from the vehicle as an assembly.
  4.  
  5. Remove or disconnect:
    CAUTION
    On some models, special tools are required for removing and installing the exhaust pipe-to-manifold spring clamps: VW3140/1 and /2 or equivalent. This is a set of different sized wedges for spreading the spring clamps in steps. The installed spring clamp has considerable tension and could cause damage or injury if not properly removed. Clamps with wedges installed are also under high tension and should be handled carefully.



    Battery cables and battery.
     
    Fuel pressure. Open the fuel filler cap to relieve tank pressure, then loosen the fuel filter fitting. Be sure to take the appropriate fire safety precautions.
     
    Engine top cover
     
    Right driveshaft
     
    Disconnect left driveshaft at transmission
     
    Radiator hoses
     
    4 bolts and front engine support
     
    Air cleaner
     
    Engine undercover
     
    Drive belt
     
    A/C compressor and wire aside
     
    Automatic transmission range selector lever
     
    All vacuum and breather hoses from engine
     
    Transmission, alternator and starter wiring
     
    Intake air pipes between charge air cooler and turbocharger
     
    Power steering pump
     
    Power steering hose mounting clamps
     
    Right CV joint cover from right side
     
    Front exhaust pipe and catalytic converter
     



    Fuel inlet and outlet lines from the injection pump and plug the holes to keep the pump clean. Note the outlet fitting has a special orifice.
     
    On turbocharged engines, exhaust pipe and the oil lines from the turbocharger and cap the oil line fittings on the turbocharger.
     
    Speedometer cable from the transaxle and plug the hole in the case.
     

  6.  
  7. Attach an engine sling tool VW-2024A or equivalent, to the engine and attach the sling to a suitable lifting device.
  8.  
  9. Remove or disconnect:

    Engine mount from engine bracket
     
    Engine transmission mount from transmission bracket
     

  10.  
  11. With all mounts unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side. Then, carefully lower the assembly out of the vehicle.
  12.  

To install:

  1. Carefully install the engine/transaxle assembly and be sure all mounts are securely bolted to the engine/transaxle. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.
  2.  
  3. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Bolts, starting at the rear and working forward: 30 ft. lbs. (40 Nm) for 10mm bolts or 44 ft. lbs. (60 Nm) for 12mm bolts.
  4.  
  5. Install or connect:

    Starter. Bolts: 50 ft. lbs. (65 Nm).
     
    Halfshafts to the flanges. Bolts: 30 ft. lbs. (40 Nm).
     
    Exhaust pipe and use new self-locking nuts to secure the flange. Nuts: 18 ft. lbs. (25 Nm). If equipped with spring clamps, the clamps can be used again.
     
    Shift linkage and the clutch slave cylinder. Make any necessary adjustments.
     
    Speedometer cable
     
    On turbocharged engines, exhaust pipe and the oil lines to the turbocharger
     
    Fuel inlet and outlet lines to the injection pump
     
    4 bolts and front engine support
     
    Right CV joint cover to right side
     
    Power steering hose mounting clamps
     
    Power steering pump
     
    Intake air pipes between charge air cooler and turbocharger
     
    Transmission, alternator and starter wiring
     
    All vacuum and breather hoses to engine
     
    Automatic transmission range selector lever
     
    A/C compressor
     
    Drive belt
     
    Engine undercover
     
    Air cleaner
     

  6.  
  7. Fill the engine with coolant and oil. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. The engine and transaxle are removed from the vehicle as an assembly.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove engine cover. To do this, jerk front of engine cover upward and then pull it forward out of rear retainer.
  8.  
  9. Remove bulkhead plenum chamber.
  10.  
  11. Remove air filter housing with Mass Air Flow (MAF) Sensor G70 and connecting pipe.
  12.  
  13. Disconnect connector at Mass Air Flow (MAF) Sensor G70.
  14.  
  15. Disconnect breather hose, as well as air guide hoses.
  16.  
  17. Remove bolt and air filter housing.
  18.  
  19. Remove battery.
  20.  
  21. Remove battery carrier.
    CAUTION
    When touching metal parts, it is possible that an electrostatic discharge could occur. The reason for this is the electrostatic charge of the human body. This charge can lead to functional problems by touching electrical components of the transmission and selector lever mechanism.

  22.  
  23. Touch a grounded object, e.g. a water pipe or a lifting platform before working on Mechatronic! Do not make direct contact with connector terminals.
  24.  
  25. Turn bayonet connection of the connector toward left and pull connector off transmission.
  26.  
  27. Release lock washer and remove upward.
  28.  
  29. Pull off lock washer upward.
  30.  
  31. Press off selector lever cable from selector shaft lever and lay it aside upward.
  32.  
  33. Slightly loosen bolts of assembly mounting on engine (less than 1 revolution).
  34.  
  35. Slightly loosen bolts of assembly mounting on transmission (less than 1 revolution).
  36.  
  37. Disconnect connector and vacuum hoses above the brake booster.
  38.  
  39. Disconnect vacuum hose at check valve for brake booster.
  40.  
  41. Disconnect vacuum hose to brake booster at tandem pump.
  42.  
  43. Disconnect coolant hoses to heater core at bulkhead.
  44.  
  45. Remove Ground (GND) wire.
  46.  
  47. Disconnect wires on starter and free up cables.
  48.  
  49. Disconnect connector at Engine Coolant Temperature (ECT) Sensor G62 .
  50.  
  51. Pull off central connector for pump injector unit by first pulling the release pin and opening the knurled nut. Then free up wiring harness.
  52.  
  53. Disconnect connector at Fuel Temperature Sensor G81 and free up wiring.
  54.  
  55. Remove coolant hose between engine and radiator.
  56.  
  57. Pull off hoses and free them up. Remove air duct. To do this, lift retaining clips slightly.
  58.  
  59. Disconnect coolant hose.
  60.  
  61. Disconnect fuel supply line and fuel return line. To do this, pull release buttons.
  62.  
  63. Disconnect coolant hose from coolant expansion tank.
  64.  
  65. Disconnect connector at Intake Flap Motor V157 .
  66.  
  67. Remove connector for Camshaft Position (CMP) Sensor G40 from bracket and disconnect it.
  68.  
  69. Disconnect connector at oil pressure switch F1 .
  70.  
  71. Unscrew oil pressure switch.
  72.  
  73. Disconnect the connector at Engine Speed (RPM) Sensor G28 with assembly tool T10118 .
    NOTE
    To release the connector without the assembly tool T10118 , push the connector against the Engine Speed (RPM) Sensor G28 and simultaneously lift up on release tab with a thin wire hook.

  74.  
  75. Free up cable and disconnect connector strip from glow plugs.
  76.  
  77. Free up wiring harnesses to body.
  78.  
  79. Remove sound insulation.
  80.  
  81. Move lock carrier into service position.
    CAUTION
    To prevent damage to condenser and also to the refrigerant lines/hoses, make sure that the lines and hoses are not stretched, kinked or bent.

  82.  
  83. To facilitate removal and installation of the engine without having to open refrigerant circuit:


    1. Remove drive belt.
    2.  
    3. Remove A/C compressor.
    4.  
    5. Secure A/C compressor to lock carrier so that refrigerant lines/hoses are not stressed.
    6.  

  84.  
  85. Remove alternator.
  86.  
  87. Remove radiator.
  88.  
  89. Remove left air duct hose, by lifting retaining clips slightly.
  90.  
  91. Remove nut and wiring bracket from threaded stud.
  92.  
  93. Remove right air duct hose, by lifting retaining clips slightly.
  94.  
  95. Disconnect connector at Engine Coolant Temperature (ECT) Sensor (on Radiator) G83.
  96.  
  97. Remove bolt for front air guide tube.
  98.  
  99. Remove right and left drive axle at transmission.
  100.  
  101. Remove front exhaust pipe.
  102.  
  103. Release connector from engine control module (ECM) and remove.
  104.  
  105. Open various retainers of cable guide.
  106.  
  107. Remove engine wiring harness from cable guide on longitudinal member and lay it aside on top of engine.
  108.  
  109. Remove right air guide tube. To do this, lift retaining clips slightly.
  110.  
  111. Remove air guide hose from turbocharger. To do this, lift retaining clip slightly.
  112.  
  113. Pull off/disconnect all electrical connections, as necessary, from engine and transmission and lay them aside.
  114.  
  115. Disconnect all connections, coolant lines, vacuum hoses and intake hoses from engine.
  116.  
  117. First remove bolt at frame, then remove the 2 bolts from the pendulum support at the transmission.
  118.  
  119. Set Engine/Trans. Support T10012 into engine/transmission jack V.A.G 1383 A.
  120.  
  121. Fasten Engine/Trans. Support T10012 to cylinder block with bolt M10 × 25/8.8 to approximately 28 ft. lbs. (40 Nm).
  122.  
  123. Lift engine and transmission slightly using engine/transmission jack V.A.G 1383 A.
    NOTE
    Use ladder VAS 5085 to remove securing bolts.

  124.  
  125. From above, unbolt assembly mounting from engine bracket on engine side.
  126.  
  127. From above, unbolt assembly mounting from transmission bracket on transmission side.
    NOTE
    Verify that all hose and line connections between engine, transmission and body have been disconnected.

  128.  
  129. While lowering, carefully guide engine/transmission assembly in order to prevent damages.
  130.  
  131. Carefully lower engine with transmission downward.
  132.  
  133. Secure engine to assembly stand using holding fixture VW 540 on holding fixture VW 313 when performing repair work.
  134.  
  135. Move engine/transmission jack V.A.G 1383 A to a work bench.
  136.  
  137. Lower engine/transmission assembly so that transmission makes contact.
  138.  
  139. Remove connecting bolts for engine/transmission.
  140.  
  141. Press transmission off from engine.
  142.  
  143. Hook in engine sling 2024 A and lift engine using shop crane V.A.G 1202 A out of engine/transmission jack V.A.G 1383 A.
    NOTE
    The peg positions on the carrying strap marked with 1 through 4 face the belt pulley. The bores in the hole rail are counted from the hook.

  144.  
  145. Secure engine using holding fixture VW 540 on holding fixture VW 313 .
  146.  

To install:

  1. Install the engine-to-transaxle attaching hardware and tighten as follows:

    M6 fasteners: 84 inch lbs. (10 Nm)
     
    M8 fasteners: 15 ft. lbs. (20 Nm)
     
    M10 fasteners: 33 ft. lbs. (45 Nm)
     
    M12 fasteners: 44 ft. lbs. (60 Nm)
     

  2.  
  3. Install the engine into the vehicle.
  4.  
  5. The remaining steps of the installation procedure is the reverse of the removal, keep in mind the following items:

    During installation, all cable ties must be re-installed at the same location
     
    Secure all hose connections with hose clamps
     
    During assembly, replace self-locking nuts and bolts
     
    Always replace bolts that are tightened to torque as well as O-rings and gaskets
     
    Make sure alignment sleeves for centering engine/transmission are installed in cylinder block. Install if necessary.
     
    Make sure that the intermediate plate is hooked in at sealing flange and is pushed onto alignment sleeves
     
    Align engine mounts so that they are free of tension, via shaking motions. If necessary, loosen engine mounts on body as well
     

  6.  
  7. Make sure that there is a 135mm clearance between engine mounting support and right longitudinal member and that the casting edge of the engine support is positioned parallel to the support arm. The dimension must be the same at top and bottom.
  8.  
  9. After installation of the engine mounting, tighten the A bolts to 14 ft. lbs. (20 Nm), plus an additional 90°; tighten the B bolts to 28 ft. lbs. (40 Nm), plus an additional 90°, and then tighten the C bolts to 41 ft. lbs. (60 Nm), plus an additional 90°.
  10.  
  11. After installation of the transmission assembly mounting, tighten the A bolts to 28 ft. lbs. (40 Nm), plus an additional 90°, and then tighten the B bolts to 41 ft. lbs. (60 Nm), plus an additional 90°.

    Click image to see an enlarged view

    Fig. Engine mounting and mounting bolts-2005-06 Jetta with 1.9L engine



    Click image to see an enlarged view

    Fig. Transmission assembly mounting and mounting bolts-2005-06 Jetta with 1.9L engine

  12.  
  13. Install pendulum support. Tighten the A bolts to 28 ft. lbs. (40 Nm), plus an additional 90°, and the B bolt to 69 ft. lbs. (100 Nm), plus an additional 90°.

    Click image to see an enlarged view

    Fig. Pendulum support and mounting bolts-2005-06 Jetta with 1.9L engine

  14.  
  15. Install drive axles.
  16.  
  17. Install front exhaust pipe.
  18.  
  19. Attach selector lever cable to transmission.
  20.  
  21. Install alternator.
  22.  
  23. Install A/C compressor.
  24.  
  25. Install drive belt.
  26.  
  27. Install sound insulation.
  28.  
  29. Install Engine Control Module (ECM).
  30.  
  31. Install bulkhead plenum chamber.
  32.  
  33. Refill the engine coolant.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Perform test drive and afterwards check DTC memory.
  38.  


NOTE
The engine is removed toward the front without the transaxle.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Engine cover and under cover.
     
    Coolant.
     
    Lock carrier with its attachments. If equipped with air conditioning, position the condenser aside leaving the hoses attached.
     
    Power steering pump and bracket, and position it aside leaving the hoses attached.
     
    Fuel supply and return lines at the fuel filter.
     
    All vacuum, coolant, and intake air hoses that would interfere with engine removal.
     
    Any electrical connections that would interfere with engine removal.
     
    Starter.
     
    Front exhaust pipe from the turbocharger.
     
    Engine-to-transaxle mounting bolts.
     

  4.  
  5. Unbolt:

    Upper left and right-hand motor mounts.
     
    Air conditioning compressor and position it aside leaving the hoses attached.
     

  6.  
  7. Using Engine Support Bracket 10-222A (or equivalent) and Transaxle Support Bracket 3147 (or equivalent) support the transaxle.
  8.  
  9. Attach an engine sling and hoist.
  10.  
  11. Raise the engine off the mounts and separate the engine from the transaxle.
  12.  
  13. Slowly lift the engine out forward.
  14.  

To install:

  1. Verify that the centering dowels are installed in the engine block, install if necessary.
  2.  
  3. Install the engine into the vehicle.
  4.  
  5. Remove the engine hoist and sling.
  6.  
  7. Remove the transaxle support apparatus.
  8.  
  9. Install the engine-to-transaxle and motor mount attaching hardware and tighten as follows:

    M6 fasteners: 84 inch lbs. (10 Nm)
     
    M8 fasteners: 15 ft. lbs. (20 Nm)
     
    M10 fasteners: 33 ft. lbs. (45 Nm)
     
    M12 fasteners: 44 ft. lbs. (60 Nm)
     

  10.  
  11. Connect the front exhaust pipe to the turbocharger.
  12.  
  13. Install the starter.
  14.  
  15. The remaining steps of the installation procedure is the reverse of the removal, keep in mind the following items:

    Be sure all electrical connections are made before connecting the battery.
     
    Install any tie-wraps that were removed.
     
    Be sure to fill the coolant and check the oil level.
     
    Check the operation of the clutch.
     
    Install the lock carrier with its attachments.
     

  16.  
  17. Connect the negative battery cable.
  18.  
  19. Install the engine cover and undercover.
  20.  
  21. Read and clear any DTCs.
  22.  

The engine and transaxle are removed from beneath the vehicle as an assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Negative battery cable.
     
    Engine cover.
     
    Power steering reservoir from the battery support leaving the hoses attached, and position it aside.
     
    Battery and bracket.
     
    Fuel supply and return lines at the fuel filter.
     
    Air cleaner and intake air duct.
     
    Throttle cable.
     
    With a manual transaxle, transaxle range selector mechanism and the clutch slave cylinder.
     
    With an automatic transaxle, range selector lever cable at the transaxle.
     
    Engine undercover.
     
    Coolant.
     
    Accessory drive belt.
     
    If necessary, right side cooling fan.
     
    Power steering pump and bracket and position it aside leaving the hoses connected.
     
    Air conditioner compressor and position it aside leaving the hoses connected.
     
    Any coolant, vacuum and intake hoses.
     
    All wires from the transaxle, starter and generator; position the wires out of the way.
     
    Any remaining wires or connectors that would interfere with the engine removal.
     
    Engine pendulum support.
     
    Right-hand halfshaft
     
    Left-hand halfshaft at the transaxle.
     
    Front exhaust pipe from the manifold.
     

  4.  
  5. Install Engine Bracket T10012, or equivalent, in the Engine/Transaxle Jack VAG 1383 A or equivalent.
  6.  
  7. Remove the bracket for the coolant hose under the engine block.
  8.  
  9. Attach the Engine Bracket T10012 to the engine block using the threaded holes at the corners of the engine block.
  10.  
  11. Raise the engine/transaxle jack to relieve the tension on the mounts.
  12.  
  13. Disconnect the engine and transaxle mounts from inside the engine compartment.
  14.  
  15. Lower the engine/transaxle assembly from the vehicle, be sure to guide the power steering pressure hose past the transaxle.
  16.  

To install:

  1. Raise the engine/transaxle assembly into the vehicle, be sure to guide the power steering hose around the transaxle.
  2.  
  3. Using new bolts, connect the engine/transaxle mounts following the accompanying illustration.

    Click image to see an enlarged view

    Fig. Exploded view of the engine mounts-New Beetle

  4.  
  5. Remove the engine/transaxle jack and Engine Bracket T10012.
  6.  
  7. Install or connect:

    Bracket for the coolant hose under the engine block.
     
    Front exhaust pipe to the manifold.
     
    Left halfshaft and right halfshaft.
     
    Engine pendulum support. Bolts (1) and (2) to 30 ft. lbs. (40 Nm) plus 90 degrees, and bolts (3) to 15 ft. lbs. (20 Nm) plus 90 degrees.

    Click image to see an enlarged view

    Fig. Pendulum support mounting bolt locations-New Beetle

     
    Any wiring that was removed.
     
    Any hoses that were removed.
     
    Air conditioner compressor.
     
    Power steering bracket and pump.
     
    If removed, right side cooling fan.
     
    Accessory drive belt and fill the cooling system.
     
    With an automatic transaxle, transaxle range selector cable.
     
    With a manual transaxle, clutch slave cylinder and connect the range selector lever.
     
    Throttle cable.
     
    Intake air duct and air cleaner assembly.
     
    Fuel supply and return lines to the filter housing.
     
    Battery bracket.
     
    Power steering reservoir.
     
    Battery cables.
     
    Engine covers.
     

  8.  

Except 2.8L Bdf Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    The engine and transaxle are lifted from the vehicle as an assembly.

  2.  
  3. Remove or disconnect:

    Battery cables and battery.
     
    Fuel pressure, by opening the fuel filler cap, loosening the fuel filter fitting. Be sure to take the appropriate fire safety precautions.
     
    Air filter
     
    Accelerator cable from the injection pump.
     
    Radiator cap. Turn the heater temperature control all the way towards warm and remove the thermostat housing to drain the coolant.
     
    Upper radiator hose and wiring from the radiator fan motor and switches.
     
    Radiator and fan shroud as an assembly.
     
    Electrical connections and vacuum lines, carefully labeling each one.
     
    With power steering, power steering pump and secure it to the body. Do not disconnect the hydraulic lines.
     
    With air conditioning, air conditioning compressor and secure it aside without disconnecting the lines.
     
    Fuel inlet and outlet lines from the injection pump and plug the holes to keep the pump clean. Note the outlet fitting has a special orifice.
     
    On turbocharged engines, exhaust pipe and the oil lines from the turbocharger and cap the oil line fittings on the turbocharger. Unbolt the turbocharger and lift it out of the engine.
     
    With an automatic transaxle, selector cable at the transaxle, with selector lever in P (park).
     
    On manual transaxle shift linkage, 2 rods with the plastic socket ends and remaining linkage from the case as required. Disconnect the clutch cable, lift it out of the case and set it aside.
     
    Wiring from the starter and the back-up light switch and the ground cable from the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
     

  4.  
  5. Attach an engine sling tool VW-2024A , to the engine and attach the sling to a suitable lifting device.
  6.  
  7. Remove or disconnect:

    Exhaust pipe from the manifold or turbocharger.
     
    Halfshafts from the flanges and hang them from the body with wire.
     
    Starter along with the front mount.
     

  8.  
  9. With all mounts unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side. Then, carefully lift the assembly out of the vehicle.
  10.  

To install:

  1. Carefully install the engine/transaxle assembly and be sure all mounts are securely bolted to the engine/transaxle. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.
  2.  
  3. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Tighten all mounting bolts, starting at the rear and working forward. Tighten to 33 ft. lbs. (41 Nm) for 10mm bolts or 54 ft. lbs. (73 Nm) for 12mm bolts.
  4.  
  5. Install or connect:

    Starter. Bolts: 33 ft. lbs. (45 Nm).
     
    Halfshafts to the flanges. Bolts: 33 ft. lbs. (45 Nm).
     
    Exhaust pipe and use new self-locking nuts to secure the flange. Nuts: 30 ft. lbs. (40 Nm). If equipped with spring clamps, the clamps can be used again.
     
    Shift linkage and the clutch cable, if equipped.
     
    Fuel injector lines and tighten to 18 ft. lbs. (25 Nm). Be careful not to over-tighten the line nuts. If a line is damaged or clogged, replace all lines as a set.
     
    Inlet and outlet lines to the injector pump, using new gaskets. Note the special outlet fitting has the word -OUT'' printed on the top.
     
    Air conditioning compressor and/or power steering pump, if equipped. Install and adjust the drive belts.
     
    Wiring and vacuum hoses.
     
    Radiator, fan and heater hoses. Use a new O-ring on the thermostat and tighten the thermostat housing bolts to 84 inch lbs. (10 Nm).
     
    Coolant
     
    Air filter.
     
    Battery and battery cables.
     

  6.  

 
label.common.footer.alt.autozoneLogo