Volkswagen Eurovan 2000-03

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  


NOTE
The engine and transaxle are lowered from the vehicle as an assembly.

  1. Relieve fuel pressure, by opening the fuel filler cap. Be sure to take the appropriate fire safety precautions.
  2.  
  3. Remove or disconnect:

    Battery cover.
     
    Battery cables and battery.
     
    Front engine cover.
     
    Ignition coils cover.
     
    Ignition coil connectors.
     
    Mass air flow (MAF) sensor hose.
     
    Throttle valve control module.
     
    Upper radiator hose and wiring from the radiator fan motor and switches.
     
    Radiator and cooling fan.
     
    Intake hose to combination valve.
     
    Secondary air injection pump.
     
    Vacuum and vent hoses carefully labeling each one.
     
    Manifold heat shield brace.
     
    Electrical connections, carefully labeling each one.
     
    Oxygen sensor connectors on subframe.
     
    Fuel supply and return lines.
     
    Remaining coolant hoses.
     
    Power steering pump and secure it to the body. Do not disconnect the hydraulic lines.
     
    Vehicle speed sensor at transaxle.
     
    Front exhaust pipe.
     
    Exhaust manifold.
     
    Catalytic converter.
     
    Air conditioning compressor and secure it aside without disconnecting the lines.
     
    Halfshafts from the flanges and hang them from the body with wire.
     

  4.  
  5. Attach engine support tool 3408 on cylinder block.
  6.  
  7. Attach an engine/transaxle jack tool VAG-1383A into support tool.
  8.  
  9. Disconnect lower engine support and subframe and transaxle.
  10.  
  11. Remove all bolts and left and right subframes.
  12.  
  13. Carefully lower the engine/transaxle assembly and remove from vehicle.
  14.  


    Click image to see an enlarged view

    Fig. Attaching engine support tool 3408



    Click image to see an enlarged view

    Fig. Removing engine support at subframe and transaxle


To install:

  1. Start all nuts and bolts that secure the subframe mounts to the body but don't tighten them yet.
  2.  


NOTE
When installing the right subframe mount, make sure the recess in engine bracket engages into the pin of the mount.

  1. Carefully install the engine/transaxle.
  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.
  4.  
  5. Torque the subframe bolts as follows: Right subframe nuts and bolt -A-: torque to 41 ft. lbs. (55 Nm), bolt -B-: torque to 37 ft. lbs. (50 Nm), plus 90°, bolt -C-: 73 inch lbs. (10 Nm). Left subframe nuts -A-: 41 ft. lbs. (55 Nm), bolts -B- and -C-: torque to 37 ft. lbs. (50 Nm), plus 90°, bolts -D-: 22 ft. lbs. (30 Nm).
  6.  
  7. Torque the engine support bolts as follows: support to subframe bolt -1-: 148 ft. lbs. (200 Nm), support to transmission bolt -2-: 59 ft. lbs. (80 Nm) plus 90°.
  8.  
  9. The remaining installation is the reverse of the removal procedure, using the following torque values.

    Starter bolts: 33 ft. lbs. (45 Nm).
     
    Halfshafts to flange bolts: 59 ft. lbs. (80 Nm).
     
    Halfshafts to wheel hub bolts: 111 ft. lbs. (150 Nm) plus 90°.
     
    Exhaust pipe to the catalytic converter. 18 ft. lbs. (25 Nm).
     
    Exhaust pipe to the exhaust manifold bolts: 30 ft. lbs. (40 Nm).
     

  10.  


    Click image to see an enlarged view

    Fig. Identifying right subframe mounting bolts



    Click image to see an enlarged view

    Fig. Identifying left subframe mounting bolts



    Click image to see an enlarged view

    Fig. Identifying engine support mounting bolts



NOTE
DTCs are stored when harness connectors are detached.

  1. Read the DTCs and clear the fault codes.
  2.  

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

  2.  
  3. Relieve fuel pressure, by opening the fuel filler cap. Be sure to take the appropriate fire safety precautions.
  4.  
  5. Remove or disconnect:

    Battery cover.
     
    Battery cables and battery.
     
    Front engine cover.
     
    Ignition coils cover.
     
    Ignition coil connectors.
     
    Mass air flow (MAF) sensor hose.
     
    Throttle valve control module.
     
    Upper radiator hose and wiring from the radiator fan motor and switches.
     
    Radiator and cooling fan.
     
    Intake hose to combination valve.
     
    Secondary air injection pump.
     
    Vacuum and vent hoses carefully labeling each one.
     
    Manifold heat shield brace.
     
    Electrical connections, carefully labeling each one.
     
    Oxygen sensor connectors on subframe.
     
    Fuel supply and return lines.
     
    Remaining coolant hoses.
     
    Power steering pump and secure it to the body. Do not disconnect the hydraulic lines.
     
    Vehicle speed sensor at transaxle.
     
    Front exhaust pipe.
     
    Exhaust manifold.
     
    Catalytic converter.
     
    Air conditioning compressor and secure it aside without disconnecting the lines.
     
    Halfshafts from the flanges and hang them from the body with wire.
     

  6.  
  7. Attach engine support tool 3408 on cylinder block.
  8.  
  9. Attach an engine/transaxle jack tool VAG-1383A into support tool.
  10.  
  11. Disconnect lower engine support and subframe and transaxle.
  12.  
  13. Remove all bolts and left and right subframes.
  14.  
  15. Carefully lower the engine/transaxle assembly and remove from vehicle.

    Click image to see an enlarged view

    Fig. Attaching engine support tool 3408



    Click image to see an enlarged view

    Fig. Removing engine support at subframe and transaxle

  16.  

To install:

  1. Start all nuts and bolts that secure the subframe mounts to the body but don't tighten them yet.
    NOTE
    When installing the right subframe mount, make sure the recess in engine bracket engages into the pin of the mount.

  2.  
  3. Carefully install the engine/transaxle.
  4.  
  5. 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.
  6.  
  7. Torque the subframe bolts as follows:

    Right subframe nuts and bolt -A-: 41 ft. lbs. (55 Nm); bolt -B-: 37 ft. lbs. (50 Nm), plus 90°; bolt -C-: 73 inch lbs. (10 Nm)
     
    Left subframe nuts -A-: 41 ft. lbs. (55 Nm); bolts -B- and -C-: 37 ft. lbs. (50 Nm), plus 90°; bolts -D-: 22 ft. lbs. (30 Nm).
     

  8.  
  9. Torque the engine support bolts as follows:

    Support to subframe bolt -1-: 148 ft. lbs. (200 Nm)
     
    Support to transmission bolt -2-: 59 ft. lbs. (80 Nm) plus 90°.

    Click image to see an enlarged view

    Fig. Identifying right subframe mounting bolts



    Click image to see an enlarged view

    Fig. Identifying left subframe mounting bolts



    Click image to see an enlarged view

    Fig. Identifying engine support mounting bolts

     

  10.  
  11. The remaining installation is the reverse of the removal procedure, using the following torque values.
    NOTE
    DTCs are stored when harness connectors are detached.



    Starter bolts: 33 ft. lbs. (45 Nm).
     
    Halfshafts to flange bolts: 59 ft. lbs. (80 Nm).
     
    Halfshafts to wheel hub bolts: 111 ft. lbs. (150 Nm) plus 90°.
     
    Exhaust pipe to the catalytic converter. 18 ft. lbs. (25 Nm).
     
    Exhaust pipe to the exhaust manifold bolts: 30 ft. lbs. (40 Nm).
     

  12.  
  13. Read the DTCs and clear the fault codes.
  14.  

 
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