Removal

NOTE:
^ The engine must be removed from above, after being separated from the transmission.
^ All tie wraps that are loosened or removed in order to remove the engine must be replaced or reinstalled in the same place when the engine is installed.
^ Determine correct radio anti-theft coding before disconnecting the battery.

1. Disconnect battery Ground (GND) strap.
- The battery is located below the rear seat bench.





2. Remove noise insulation panel (7 fasteners).
3. Disconnect bracket for noise insulation panel on engine mount.





4. Drain engine coolant at drain plug (arrow) using special tool No. 3247, or equivalent.
5. Drain radiator using drain plug at bottom right of radiator.





6. Remove intake air duct between Mass Air Flow (MAF) sensor and intake manifold.
7. Disconnect harness connectors from MAF sensor and Idle Air Control (IAC) valve.
8. Remove intake air preheating hose.
9. Remove EVAP canister purge regulator valve on MAF sensor.
- Unclip air cleaner housing and remove with MAF sensor.

NOTE: All illustrations are shown with covering removed.





10. Remove cover on intake air housing, remove both screws, push back and lift housing.
11. Remove both positive crankcase ventilation breather hoses, disconnect vacuum hose and remove intake air housing.
12. Remove coolant hose between radiator and top of engine.





13. Remove both covers for fuel injection lines on left and right sides.
14. Disconnect fuel injector harness connectors and place aside at rear together with the covers.





15. Remove ignition coil cover (arrow).
16. Mark which ignition wires go to which spark plugs.
17. Disconnect wires from ignition coil.





18. Disconnect harness connectors (arrows) attached to bracket on engine compartment bulkhead near plenum chamber.
19. Cut tie-wraps and disconnect wires as necessary.





20. Remove ignition coils with ignition coil holder.
21. Pull ignition coil wires forward (toward fan) and out from beneath intake manifold.





22. Disconnect fuel supply line -1- and fuel return line -2- from fuel rail.





23. Disconnect vacuum hose on intake manifold and remove vacuum pump (if installed).
24. Disconnect accelerator pedal cable from throttle body and move to one side.
25. Disconnect hose between EVAP canister purge regulator valve and throttle body.
26. Disconnect Heated Oxygen Sensor (HO2S) connector at right and uncover wires.





27. Disconnect harness connector on plenum chamber at left.
28. Disconnect harness connectors from oil pressure sensor and oil pressure switch.
29. Disconnect harness connectors for cruise control system, intake manifold change-over valve (blue) and EGR valve (brown).
30. Disconnect crankshaft position sensor harness connector at rear of left-side cylinder head.
31. Disconnect harness connector from throttle position sensor.





32. Clamp off engine coolant hose using hose clamp tool No. 3094, Snap-On YA 2850, or equivalent.
- Pull off hose at pump and holder at bottom, uncover.
33. Remove cover for ribbed belt.





34. Disconnect pressure line from power steering pump (left arrow).
35. Use rag to absorb any oil spills.





36. Remove coolant hose on right side, together with coolant line.
37. Remove nut from engine support.





38. Disconnect GND strap from right side engine support (right arrow).
39. Remove nut from engine support (left arrow).





40. Relieve tension on ribbed belt, using drift tool No. 3204, or equivalent, to secure belt.
41. Remove ribbed belt.
42. Disconnect both heater hoses from engine at left rear.





43. Remove air guide for generator.
44. Remove clamp on oil pan.

NOTE: Make sure battery been disconnected.

45. Remove generator (wires remain connected) and tie-up onto one side.
46. Unbolt starter and pull out toward rear (wires remain connected).
47. Tie-up starter to engine at one side.





48. Remove crossmember.
48. Disconnect and remove three way catalytic converters.
50. Remove clamp for AIC compressor line on cross member at front.
51. Remove oil filter.
52. Loosen and remove oil cooler from under oil filter.





53. Unscrew bolts and secure A/C compressor to one side with wire.

NOTE:
^ Disconnect brackets and mounting points only.
^ DO NOT open the air conditioning refrigerant circuit.
^ Refrigerant lines kink easily.
^ The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.

54. Unbolt engine/transmission flange at bottom and top.





55. Support weight of transmission using engine support bridge tool No. 10-222A and hook tool No. 3147, or equivalents.
- Shown with engine removed.





56. Attach engine sling tool No. 2024A, or equivalent at right-rear and left-front of engine, and secure.

NOTE: In order to balance the engine's center of gravity, the rail holes of the engine sling must be arranged as illustrated.

57. Attach workshop crane to engine sling.
58. Lift engine slightly.





59. Remove front engine support from side member (arrows) (partially loosen applicable inner fender liner).
60. Carefully lift engine while turning support bridge until clear of right mount.
61. Carefully pull engine forward until it is completely clear.
62. Lift out starter after engine has been separated from transmission.
63. Lift engine up and out.





64. Mount engine to stand using engine holder tool No. VW 540, or equivalent, along with tool No. VW 540/1 A or equivalent.