Volkswagen Cars 2000-05

Engine 5

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Removal & Installation



Gasoline Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Tag all hoses and wiring during removal, to use as reference during reassembly.

  2.  
  3. 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. Remove the 3 quick-release screws on the front noise insulation panel.
    6.  
    7. Unbolt the air guide between the lock carrier and the air filter.
    8.  
    9. If installed, remove the retaining clamps for the wiring harness at the left side of the radiator frame.
    10.  
    11. Remove the No. 2 bolts and install Support tool 3369 .
    12.  
    13. Remove the remaining bolts and pull the lock carrier out to the stop.
    14.  
    15. 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-Passat

    16.  

  4.  
  5. Position the wipers to the vertical position.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect:
    WARNING
    The flexpipe at the front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.



    Negative battery cable.
     
    Engine under cover.
     
    Coolant.
     
    Front bumper.
     
    Power steering cooling coil from the radiator, leaving it connected and hanging.
     
    If equipped, transaxle oil cooling lines.
     
    Electric cooling fan thermal switch at the lower left of the radiator.
     
    Air intake duct and assembly.
     
    Headlight height adjuster wiring harness.
     
    Turn signal bulbs from the light housing.
     
    Coolant hose from the radiator at the upper coolant pipe.
     
    Hood release cable at the carrier lock.
     
    Power steering fluid reservoir cap/dipstick.
     
    Wiring harness for the ABS hydraulic unit.
     
    Horn electrical connectors.
     
    Air guides at the left and right sides of the radiator.
     
    Air conditioning condenser retaining fasteners.
     
    Air conditioning low pressure switch.
     
    Condenser, and position it over the fender.
     
    Green harness connector from the air conditioning compressor magnetic clutch.
     
    Engine covers.
     
    Wiring harness connectors for the wastegate bypass regulator valve, the EVAP canister purge regulator valve, the power output stage, and the MAF sensor.
     
    ECL warning switch.
     
    Coolant hoses at the expansion tank, then remove the tank and position it aside.
     
    With cruise control, actuating rod from the throttle valve control module, then remove the vacuum hose from the vacuum unit.
     
    Accelerator pedal cable from the throttle valve control module.
     
    Hose for the Leak Detection Pump (LDP).
     
    Fuel supply and return lines.
     
    Brake booster vacuum hose.
     
    Vacuum hose for the EVAP canister purge regulator valve.
     
    ECM retaining bracket.
     
    Wiring harness to the ECM.
     
    With an automatic transaxle, the kickdown switch connector.
     
    Heated oxygen sensor wiring harness.
     
    Ground connection at the plenum chamber.
     
    Heater hoses from the heater core.
     
    VSS from the transaxle and position it aside.
     
    With a manual transaxle, back-up light switch from the transaxle.
     
    Engine driven cooling fan.
     
    Accessory drive belts.
     
    Air conditioning compressor from the mounting bracket and position it aside using wire.
     
    Power steering pump and position it aside leaving the hoses attached.
     



    Catalytic converter from the turbocharger.
     
    Starter, and the ground strap at the right engine mount.
     
    With an automatic transaxle, 3 torque converter-to-driveplate mounting bolts through the opening left by the starter.
     

  10.  
  11. Loosen the upper nuts for the left and right engine mounts, matchmark the threaded bolt and centering sleeves at the bottom of the left and right engine mounts, then remove the mounting nuts.
  12.  
  13. Remove or disconnect:

    Lower engine-to-transaxle mounting bolts.
     
    With an automatic transaxle, ATF cooler line bracket form the left side of the engine.
     
    Upper nuts from the engine mounts.
     

  14.  
  15. Position an Engine Support Bridge 10-222A to the bolted flanges of the fenders with the spindle facing forward.
  16.  
  17. Attach the Engine Support Adapter 3147 or equivalent to a bolt hole in the transaxle bell housing.
  18.  
  19. Connect the Engine Support Adapter 3147 and the Engine Support Bridge 10-222A using Adapter 2024A/1 and Extension 2024A/2.
  20.  
  21. Attach an engine sling between the engine and the hoist.
  22.  
  23. Remove the upper engine-to-transaxle mounting bolts.
  24.  
  25. Separate the engine from the transaxle, then slowly lift the engine up and out the front of the engine compartment.
  26.  
  27. If equipped with an automatic transaxle, secure the torque converter to prevent it from falling out.
  28.  

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 or connect the following:

    Engine into the vehicle
     
    Upper engine-to-transaxle mounting bolts
     

  4.  
  5. Lower the engine into position, then remove the engine sling and hoist and the transaxle support apparatus from the vehicle.
  6.  
  7. Install or connect:

    Engine mounting fasteners without any tension or pre-load.
     
    With an automatic transaxle, ATF cooler line bracket to the left side of the engine.
     
    Lower engine-to-transaxle mounting bolts. M12 bolts: 48 ft. lbs. (65 Nm), M10 bolts: 33 ft. lbs. (45 Nm)
     
    Engine mounting nuts/bolts: 18 ft. lbs. (25 Nm).
     
    With an automatic transaxle, driveplate-to-torque converter mounting bolts through the starter opening. Bolts: 63 ft. lbs. (85 Nm).
     
    Starter and attach the ground strap to the right engine mount.
     
    Catalytic converter to the turbocharger. Mounting bolts: 22 ft. lbs. (30 Nm).
     
    Power steering pump, the air conditioning compressor, and the engine cooling fan, then the accessory drive belts.
     
    With a manual transaxle, back-up light switch to the transaxle.
     
    VSS to the transaxle.
     
    Heater hoses to the heater core.
     
    Ground connection at the plenum chamber.
     
    Heated oxygen sensor wiring harness.
     
    With an automatic transaxle, kickdown switch connector.
     
    Wiring harness to the ECM.
     
    ECM retaining bracket and cover the E-box.
     
    Vacuum hose for the EVAP canister purge regulator valve.
     
    Fuel supply and return lines.
     
    Brake booster vacuum hose.
     

  8.  
  9. The completion of the installation procedure is the reverse of the removal.
  10.  
  11. If equipped with an automatic transaxle, check the ATF level
  12.  
  13. Fill the engine with coolant
  14.  
  15. 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
  16.  
  17. Connect the negative battery cable.
    NOTE
    DTCs are stored when harness connectors are detached.

  18.  
  19. Read the DTCs and clear the fault codes.
  20.  

The engine and transaxle are removed from under 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 positioning it aside.
     
    Battery and bracket.
     
    Fuel supply and return lines.
     
    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.
     
    Coolant, vacuum and intake hoses.
     
    Secondary air injection pump and bracket.
     
    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 and disconnect the left-hand halfshaft at the transaxle.
     
    Front exhaust pipe from the manifold.
     

  4.  
  5. Install Engine Bracket T10012, or equivalent, in 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. Engine mount fastener locations-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 the right halfshaft.
     
    Engine pendulum support. Bolts (1) and (2): 30 ft. lbs. (40 Nm) plus 90 degrees, and bolts (3): 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.
     
    Secondary air injection pump and bracket.
     
    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, the 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.
     
    Battery bracket.
     
    Power steering reservoir.
     
    Engine oil.
     
    Battery cables.
     

  8.  
  9. Check and clear any DTCs, then match the ECM to the TCM.
  10.  
  11. Install the engine covers.
  12.  

4 Cyl.

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.


NOTE
On the 8 valve engines, special tools are required to remove and install the exhaust pipe to manifold spring clamps. These may be available at local parts retailers.


CAUTION
Fuel lines may be pressurized. Make sure the work area is well ventilated. Vapors can easily ignite.

  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 by completing the following:

    Remove the fuel filler cap to relieve tank pressure.
     
    Loosen the cold start injector line to relieve the fuel system pressure on CIS-E fuel injection systems.
     
    On Digifant fuel injection, 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 coolant 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. On Golf and Jetta, the front body section must be removed:

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

  20.  
  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.
  2.  


NOTE
You may not have to disconnect the hydraulic lines and secure them out of the way.

  1. The entire fuel injection system can be removed as a unit if the vehicle is equipped with the CIS-E type.

    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.



As you remove the cold start injector, tape all the injector lines together and set them aside.
 
Detach the wiring and the fuel supply line from the fuel distributor. Plug the fuel inlet to keep dirt out of the fuel distributor.
 
Disconnect the fuel return line from the pressure regulator.
 
Remove the bolts or clips required to change the air filter and lift the air flow sensor and fuel system out of the vehicle.
 

  1. On engines with Digifant fuel injection, 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, place the selector lever in the "PARK" position and 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, remove the 2 rods with the plastic socket ends and unbolt the remaining linkage from the transaxle case as required. Disconnect the clutch cable, lift it from the case and set it aside.
  6.  
  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. Unbolt the halfshafts from the flanges and hang them from the body with wire.
  12.  


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

  1. Unbolt the exhaust pipe from the manifold or remove the spring clamps holding the exhaust pipe to the manifold and lower the pipe.
  2.  
  3. If the exhaust pipe is secured to the manifold with spring clamps, use the proper tools and procedures for removal and installation.
  4.  


CAUTION
The springs are under heavy tension and can cause serious injury if mishandled.

  1. To remove the 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.
     
    Leave the wedges in the clamps and put them in a box so they won't be disturbed and fly apart.
     

  2.  
  3. Attach a suitable chain sling to the lifting eyes.
  4.  


NOTE
On 16V engines, a rigid sling must be used. Remove the idle stabilizer valve and upper intake manifold and attach engine sling tool 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. Next, carefully lift the assembly from the vehicle. See Section 7 for information on separating the engine and transaxle.
  6.  

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. Attach the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Connect the exhaust pipe. On 16V engines, use new self locking nuts to secure the flange and torque the nuts to 30 ft. lbs. (40 Nm).
  8.  
  9. Attach the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  10.  
  11. Install the fuel system components and connect the lines.
  12.  
  13. On Golf and Jetta, install the front apron and connect the wiring.
  14.  
  15. Install the air conditioning compressor and/or power steering pump, if equipped. Install and adjust the drive belts.
  16.  
  17. Install the radiator, fan and heater hoses.
  18.  
  19. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  20.  
  21. Connect all remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  22.  
  23. Fill the cooling system. Check the adjustment of the accelerator cable.
  24.  

Vr-6


Click image to see an enlarged view

Fig. The use of a narrow 15°V-6 allows VW to fit a more powerful engine (such as this VR6) where others cannot


NOTE
The factory audio system is coded. Know your code before you remove the battery cables.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the engine accessory drive belt.
  6.  


NOTE
General practice is to mark the accessory drive belt's rotation before removing the belt. This will aid in the installation of the belt.

  1. Remove the spark plug connectors from the plugs, then remove the plug wire guides.
  2.  


NOTE
A special tool is required to remove the spark plug connectors from the plugs. A version of this tool is connected to the front hood support bar.

  1. Remove the round harness connector near the ignition coil on the rear of the cylinder head.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Label and then disconnect all wires, hoses, and clips attached to the cylinder head.
  6.  
  7. Remove the air filter housing and intake air ducts. This only applies to vehicles with mass air flow sensors.
  8.  
  9. Disconnect the accelerator cable from the throttle.
  10.  
  11. Label then disconnect the fuel hoses from the cylinder head and position them out of the way.
  12.  
  13. Remove all necessary coolant hoses.
  14.  
  15. Detach the exhaust pipes from the manifolds.
  16.  
  17. Remove the drive axles.
  18.  
  19. Remove the radiator mounting bolts.
  20.  
  21. If the vehicle has A/C, remove all necessary components. This will require the skills of a certified technician to evacuate the refrigerant from the system.
  22.  
  23. Detach the front body mounting bolts.
  24.  
  25. Remove all remaining electrical connectors, hoses, and brackets from the radiator assembly.
  26.  
  27. On vehicles with A/C, remove the radiator and the A/C condenser as a unit.
  28.  
  29. Unbolt and remove the power steering pump from its bracket and set it to the side.
  30.  
  31. Remove the electrical harness connectors from the transmission-automatic transmission equipped vehicles.
  32.  
  33. Detach the transmission cooler lines from the transmission-automatic transmission equipped vehicles.
  34.  
  35. Remove the clutch slave cylinder on manual transmission vehicles.
  36.  
  37. On automatic transmission equipped vehicles, place the selector lever in the park position.
  38.  
  39. Label the starter wiring from the starter. Then remove the wiring from the alternator.
  40.  
  41. Remove the intake air temperature sensor (IAT).
  42.  
  43. Install the engine hoist.
  44.  



Click image to see an enlarged view

Fig. Installation of an engine hoist

  1. Remove the motor mounts.
  2.  



Click image to see an enlarged view

Fig. Remove the motor mounts

  1. Raise the engine and transmission from the vehicle.
  2.  

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. Properly torque all motor mount nuts and bolts. See included art for torque specs.
  2.  



Click image to see an enlarged view

Fig. Engine/transaxle mount-front



Click image to see an enlarged view

Fig. Engine/transaxle mount-right rear



Click image to see an enlarged view

Fig. Engine/transaxle mount-left rear

  1. Using the engine hoist, lower the engine into the bay.
  2.  
  3. Install the front body assembly
  4.  
  5. Install all removed components, connectors, hoses, lines, etc.
  6.  
  7. The remainder of the installation process is the reverse of removal.
  8.  


NOTE
Tighten the drive axle flange bolts to 33 ft. lbs. (45 Nm) and the exhaust pipe to exhaust manifold to 30 ft. lbs. (40 Nm).

Vr6

The VR6 engine has a unique 15° V-angle between its cylinder banks. Traditional 60 or 90° engines require a great deal of engine compartment space. VW's compact VR6 was designed to enable it to fit into a chassis that was originally designed to accommodate a longitudinal inline 4-cylinder engine. The VR6 consists of a cast iron block with a one-piece aluminum alloy cylinder head.


NOTE
The engine was named the VR6 through the combination of two words. Vee (a reference to the configuration of the cylinders) and Reihenmotor (a German word for 'inline'). Engineers were essentially referring to it as an inline V-6.

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.  


NOTE
The factory audio system is coded. Know your code before you remove the battery cables.

  1. Disconnect the negative battery cable.
  2.  


NOTE
General practice is to mark the accessory drive belt's rotation before removing the belt. This will help to prevent premature failure of the belt.

  1. Noting its direction or rotation, remove the engine accessory drive belt.
  2.  


NOTE
A special tool is required to remove the spark plug connectors from the plugs. A version of this tool is connected to the front hood support bar.

  1. Remove the air filter housing and intake air ducts.
  2.  
  3. Remove the spark plug connectors from the plugs as follows:
  4.  
    1. Using the provided removal tool which should be attached to the hood support bar, place the tool into the spark plug cavity over the connector until it bottoms.
    2.  
    3. Turn the tool clockwise about 1 / 8 of a turn, then pull upward to release the connector.
    4.  

  5. Label, then remove the spark plug wires and wire guides.
  6.  
  7. Remove the round harness connector near the ignition coil on the rear of the cylinder head.
  8.  
  9. Remove the intake manifold cover.
  10.  
  11. Disconnect the accelerator cable from the throttle body, but Do NOT remove the locating clip at the support bracket.
  12.  
  13. Loosen hose clamp for the power steering reservoir.
  14.  
  15. Remove the power steering lines from the retainers from the transaxle and the engine mount. Do NOT disconnect the lines.
  16.  
  17. Remove the power steering pump assembly from the engine, leaving the hoses attached, and place the pump aside. Secure the pump using mechanic's wire or its equivalent.
  18.  
  19. Remove the upper radiator support/hood latch carrier assembly from the front of the vehicle. Trace the outline of the fasteners for proper alignment during assembly. If equipped with A/C, release all the retaining clips for the high pressure lines, but Do NOT disconnect them.
  20.  
  21. Drain the cooling system into a suitable container.
  22.  
  23. Locate and disconnect the 42-pin electrical connector near the coil assembly.
  24.  
  25. Disconnect the wiring and place aside from the following components:
  26.  


    Transaxle assembly
     
    Alternator
     
    Starter Motor
     

  27. Disconnect all of the vacuum, breather and coolant hoses from the engine.
  28.  
  29. Carefully relieve the fuel system pressure.
  30.  
  31. Cover the connections with a suitable shop cloth and disconnect the fuel feed and return lines from the fuel rail assembly, then release the lines from their retainers on the cylinder head cover.
  32.  
  33. Disconnect the electrical connectors for the 2-pin Knock (KS) Sensor 1 at the right rear and the 4-pin connector for the Oxygen (O 2 S) Sensor probe.
  34.  
  35. 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.
  36.  
  37. 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.
  38.  
  39. 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 (50mm) 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.
  40.  


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

  1. Remove the ballast weight and front exhaust pipe from the exhaust manifold.
  2.  
  3. Remove the vacuum hose from the fuel pressure regulator and the upper section of the intake manifold.
  4.  
  5. Remove the absolute pressure regulator from the upper intake manifold.
  6.  
  7. If NOT equipped with air conditioning, remove the radiator assembly complete with the cooling fan and the air ducts.
  8.  

If equipped with air conditioning observe the following guidelines:



Do NOT disconnect the high-pressure hoses
 
Do NOT kink the high-pressure hoses
 
Support removed components to avoid stress on the hoses
 

  1. If equipped with air conditioning proceed as follows:
  2.  
    1. Remove the mounting fasteners for the A/C fluid reservoir. Allow the reservoir to hang freely.
    2.  
    3. Remove all of the high pressure refrigerant line retaining clamps.
    4.  
    5. If not previously removed, label the ribbed belt's direction and remove.
    6.  
    7. Remove the A/C compressor from its mounting bracket.
    8.  
    9. Leaving the A/C hoses attached, carefully remove the radiator assembly complete with the condenser and A/C compressor, moving the left side (driver's side) of the radiator and A/C condenser forward such that the radiator and condenser are moved about 90° from their mounting points.
    10.  
    11. Support the radiator and condenser assembly upright by supporting the fan with a block of wood. Support the compressor pulley side down on a block of wood, such that the hoses are not kinked or stressed.
    12.  

  3. On vehicles with a manual transaxle:
  4.  
    1. Remove the clutch slave cylinder.
    2.  
    3. Disconnect the transaxle shift linkage cables along with their support bracket.
    4.  
    5. Attach engine lifting sling Tool No. 2024 A or its equivalent such that the vibration damper end of the engine is mounted to the 4th hole in hook position 1 and the flywheel end in the 4th hole in hook position 6. Make sure all hooks and locating pins are secured with locking pins.
    6.  

  5. On vehicles with an automatic transaxle:
  6.  
    1. Disconnect the transaxle gear selector cable.
    2.  
    3. Attach engine lifting sling Tool No. 2024 A, or its equivalent, such that the vibration damper end of the engine is mounted to the 1st hole in hook position 1 and the flywheel end in the 3rd hole in hook position 6. Make sure all hooks and locating pins are secured with locking pins.
    4.  

  7. Using a suitable engine hoist, carefully lift the engine slightly to release the engine from the right rear mounting point and the transaxle from the left rear mounting point.
  8.  
  9. Disconnect and release the engine from the front engine mount.
  10.  
  11. With the engine carrier disconnected at the power steering lines, carefully release the spacer bracket from the rubber mountings on the disconnected engine carrier, then disconnect the power steering lines from the engine carrier releasing the assembly forward as necessary.
  12.  
  13. 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.
  14.  
  15. 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.
  16.  
  17. 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.
  18.  
  19. 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.
  20.  



Click image to see an enlarged view

Fig. The use of a narrow 15°V-6 allows installation of a larger displacement engine into a compact engine compartment



Click image to see an enlarged view

Fig. Installation of an engine hoist

  1. Remove the motor mounts.
  2.  



Click image to see an enlarged view

Fig. Remove the motor mounts



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Fig. Engine/transaxle-front



Click image to see an enlarged view

Fig. Engine/transaxle mount-right rear



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Fig. Engine/transaxle mount-left rear

To install:

  1. Installation is in reverse order of assembly, noting the following key points.
  2.  
  3. 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.
  4.  
  5. On vehicles with an automatic transaxle, make sure to fasten the torque converter to the flexplate.
  6.  
  7. Make sure all mount brackets are securely bolted to the engine/transaxle.
  8.  
  9. Carefully lower the assembly into the engine bay making sure there is adequate room between the axles.
  10.  
  11. Make sure to position the mounts such that the recessed area on the engine mount brackets fits correctly over the lugs on the engine mounts.
  12.  
  13. Start all nuts and bolts that secure the mounts to the body, but don't tighten them yet.
  14.  
  15. With all mounts installed but not tightened fully and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, rock the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at front, then the rear and finally the left rear.
  16.  

Observe the following tightening torque upon assembly:



Engine mount M8 fasteners: 18 ft. lbs. (25 Nm)
 
Engine to transaxle M10: 44 ft. lbs. (60 Nm)
 
Engine to transaxle M12: 59 ft. lbs. (80 Nm)
 
Driveshaft flange bolts: 33 ft. lbs. (45 Nm)
 
Engine mount to vehicle body: 59 ft. lbs. (80 Nm)
 
Engine mount bracket-to-engine through bolt: 44 ft. lbs. (60 Nm)
 
Front pipe to exhaust manifold: 30 ft. lbs. (40 Nm)
 
Front pipe top catalytic converter: 18 ft. lbs. (25 Nm)
 

  1. 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.
  2.  
  3. 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.
  4.  
  5. Check the adjustment of the accelerator cable and adjust as necessary.
  6.  
  7. Start the engine, check for fluid leaks, test drive and check for normal operation.
  8.  

 
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