Monday, November 21, 2011

How to Replace Engine on Audi A4 And VW Passat Car Models?


If you need dis-assembly or replacement instructions for any other auto/car part, or you want to ask question related to your car/truck jeep problem then please leave the comment with your details, so I can provide you the required instructions and solutions.

The procedure is as follows :----

Engine


REMOVAL & INSTALLATION
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 noteguide 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 guide.
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 in this guide.


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.

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. If your vehicle is equipped with an anti-theft system, know your deactivation code before you remove any of the battery cables.
  3. Relieve the fuel system pressure as follows:
    1. Remove the fuel filler cap to relieve tank pressure.
    2. On 9A engines, loosen the cold start injector line to relieve the fuel system pressure on CIS-E fuel injection systems.
    3. On ABA engines, loosen the pressure test port fitting at the end of the fuel rail that supplies the injectors.
  4. The air intake duct between the air cleaner and the throttle body must also be removed.
  5. Detach the accelerator cable from the throttle and remove the cable housing from the bracket.
  6. Set the heater temperature control to maximum.
  7. Remove the radiator cap and place a pan under the thermostat housing and remove the thermostat flange to drain the coolant.
  8. Remove the air conditioner compressor and the condenser without disconnecting the pressure lines and secure them out of the way.
  9. 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.
  10. Remove the front upper radiator support/hood latch support as follows:
    1. Detach the headlight electrical connectors and the hood release cable from the hood latch assembly.
    2. Remove the lower valance and the front grille, and front apron.
  11. Disconnect all electrical connections and vacuum lines, carefully labeling each one.

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. On 9A engines, the entire fuel injection system can be removed as a unit as follows:
    1. Without disconnecting the lines, carefully pry the injectors from their holes and protect them with caps.

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. Detach the wiring and the fuel supply line from the fuel distributor. Plug the fuel inlet to keep dirt out of the fuel distributor.
  3. Disconnect the fuel return line from the pressure regulator.
  4. 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.
  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. If equipped with an automatic transaxle,
    1. Place the selector lever in the "PARK" position.
    2. Disconnect the shifter cable at the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
  3. On vehicles with a manual transaxle,
    1. Remove the 2 rods with the plastic socket ends and unbolt the remaining linkage from the transaxle case as required.
    2. Disconnect the clutch cable, lift it from the case and set it aside.
  4. 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.
  5. Raise and safely support the vehicle on jack stands.
  6. 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.

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. 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.
  3. 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.

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. Attach a suitable chain sling to the lifting eyes.

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. Once all of the mounts have been unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side.
  3. 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.
  4. 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.
  5. 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.
  6. 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.
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. On vehicles with an automatic transaxle, make sure to fasten the torque converter to the flexplate.
  3. 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.
  4. 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.
  5. Install the starter and torque the bolts to 33 ft. lbs. (45 Nm).
  6. Attach the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  7. 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).
  8. As necessary, attach the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  9. Install the fuel system components and connect the lines. Lubricate all fuel line O-rings with a light coating of fresh engine oil.
  10. Install the front upper radiator/hood lock support and connect the wiring.
  11. If equipped, install the air conditioning compressor and/or power steering pump, then install and adjust the drive belts.
  12. Install the radiator, fan and heater hoses.
  13. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  14. Connect all of the remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  15. 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.
  16. 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.
  17. Check the adjustment of the accelerator cable and adjust as necessary.
  18. Start the engine, check for fluid leaks, test drive and check for normal operation.
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. If your vehicle is equipped with an anti-theft system, know your deactivation code before you remove any of the battery cables.

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

  1. Disconnect the negative battery cable.

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.

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. Remove the spark plug connectors from the plugs as follows:
    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. Turn the tool clockwise about 1 / 8 of a turn, then pull upward to release the connector.
  3. Label, then remove the spark plug wires and wire guides.
  4. Remove the round harness connector near the ignition coil on the rear of the cylinder head.
  5. Remove the intake manifold cover.
  6. Disconnect the accelerator cable from the throttle body, but Do NOT remove the locating clip at the support bracket.
  7. Loosen hose clamp for the power steering reservoir.
  8. Remove the power steering lines from the retainers from the transaxle and the engine mount. Do NOT disconnect the lines.
  9. 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.
  10. 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.
  11. Drain the cooling system into a suitable container.
  12. Locate and disconnect the 42-pin electrical connector near the coil assembly.
  13. Disconnect the wiring and place aside from the following components:
  14. Transaxle assembly
  15. Alternator
  16. Starter Motor
  17. Disconnect all of the vacuum, breather and coolant hoses from the engine.
  18. Carefully relieve the fuel system pressure.
  19. 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.
  20. 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.
  21. 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.
  22. 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.
  23. 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.

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. Remove the vacuum hose from the fuel pressure regulator and the upper section of the intake manifold.
  3. Remove the absolute pressure regulator from the upper intake manifold.
  4. If NOT equipped with air conditioning, remove the radiator assembly complete with the cooling fan and the air ducts.
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:
    1. Remove the mounting fasteners for the A/C fluid reservoir. Allow the reservoir to hang freely.
    2. Remove all of the high pressure refrigerant line retaining clamps.
    3. If not previously removed, label the ribbed belt's direction and remove.
    4. Remove the A/C compressor from its mounting bracket.
    5. 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.
    6. 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.
  2. On vehicles with a manual transaxle:
    1. Remove the clutch slave cylinder.
    2. Disconnect the transaxle shift linkage cables along with their support bracket.
    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 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.
  3. On vehicles with an automatic transaxle:
    1. Disconnect the transaxle gear selector cable.
    2. 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. 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.
  5. Disconnect and release the engine from the front engine mount.
  6. 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.
  7. 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.
  8. 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.
  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. 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.


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


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Fig. Installation of an engine hoist
  1. Remove the motor mounts.


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Fig. Remove the motor mounts


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Fig. Engine/transaxle-front


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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. 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.
  3. On vehicles with an automatic transaxle, make sure to fasten the torque converter to the flexplate.
  4. Make sure all mount brackets are securely bolted to the engine/transaxle.
  5. Carefully lower the assembly into the engine bay making sure there is adequate room between the axles.
  6. 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.
  7. Start all nuts and bolts that secure the mounts to the body, but don't tighten them yet.
  8. 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.
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. 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.
  3. Check the adjustment of the accelerator cable and adjust as necessary.
  4. Start the engine, check for fluid leaks, test drive and check for normal operation.
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 in the beginning of this section.
  2. Obtain the radio security code.
  3. Turn the ignition switch to the OFF position, and then disconnect the negative battery cable.
  4. Position the wipers to the vertical position.
  5. Properly relieve the fuel system pressure.
  6. Disconnect the negative battery cable.
  7. Remove the lower engine slash shield.
  8. 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.
  9. Remove the front bumper. For additional information, please refer to the following topic(s): Body And Trim, Front Bumper.
  10. Remove the front hood lock carrier assembly. For additional information, please refer to the following topic(s): Body And Trim, Hood Lock Carrier.
  11. Disconnect the air conditioning low-pressure switch.
  12. Detach the green harness connector from the air conditioning compressor magnetic clutch.
  13. Remove the engine covers.
  14. 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.
  15. Detach the Engine Coolant Level (ECL) warning switch.
  16. Disconnect the coolant hoses at the expansion tank, then remove the tank and position it aside.
  17. If equipped with cruise control, detach the actuating rod from the throttle valve control module, then remove the vacuum hose from the vacuum unit.
  18. Detach the accelerator pedal cable from the throttle valve control module.
  19. Remove the hose for the Leak Detection Pump (LDP).
  20. Disconnect the fuel supply and return lines.
  21. Disconnect the brake booster vacuum hose.
  22. Remove the vacuum hose for the Evaporative Emissions (EVAP) canister purge regulator valve.
  23. Uncover the E-box.
  24. Unclip the Motronic Engine Control Module (ECM) retaining bracket.
  25. Detach the wiring harness to the ECM.
  26. If equipped with an automatic transaxle, detach the kickdown switch connector.
  27. Detach the heated oxygen (O 2 S) sensor wiring harness.
  28. Detach the ground connection at the plenum chamber.
  29. Disconnect the heater hoses from the heater core.
  30. Detach the Vehicle Speed Sensor (VSS) from the transaxle and position it aside.
  31. If equipped with a manual transaxle, detach the backup light switch connector from the transaxle.
  32. Remove the engine driven cooling fan.
  33. Remove the accessory drive belts.
  34. Unbolt the air conditioning compressor from the mounting bracket and position it aside and properly secure.
  35. Disconnect the power steering pump and position it aside leaving the hoses attached.

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. Remove the starter, and the ground strap at the right engine mount.
  3. If equipped with an automatic transaxle, remove the 3 torque converter-to-driveplate mounting bolts through the opening left by the starter.
  4. Loosen the upper nuts for the left and right engine mounts.
  5. 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.
  6. Remove the lower engine-to-transaxle mounting bolts.
  7. If equipped with an automatic transaxle, remove the cooler line bracket form the left side of the engine.
  8. Remove the upper nuts from the engine mounts.
  9. Position an engine support bridge tool No. 10-222A, or equivalent, to the bolted flanges of the fenders with the spindle facing forward.
  10. Attach the support adapter tool No. 3147, or equivalent, to the bolt hole above the starter mounting area in the transaxle bell housing.
  11. 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.
  12. Attach a suitable engine sling between the engine and the hoist.
  13. Remove the upper engine-to-transaxle mounting bolts.
  14. Separate the engine from the transaxle, then slowly lift the engine up and out the front of the engine compartment.
  15. If equipped with an automatic transaxle, secure the torque converter to prevent it from falling out.


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


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


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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


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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. Install the engine into the vehicle.
  3. Install the upper engine-to-transaxle mounting bolts.
  4. Lower the engine into position, then remove the engine sling and hoist.
  5. Remove the transaxle support apparatus from the vehicle.
  6. Install the engine mounting fasteners without any tension or pre-load.
  7. If equipped with an automatic transaxle, install the transmission cooler line bracket to the left side of the engine.
  8. Install the lower engine-to-transaxle mounting bolts, and tighten the mounting bolts as follows:
  9. M12 bolts: 48 ft. lbs. (65 Nm)
  10. M10 bolts: 33 ft. lbs. (45 Nm)
  11. Tighten the engine mounting fasteners to 18 ft. lbs. (25 Nm).
  12. 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).
  13. Install the starter and attach the ground strap to the right engine mount.
  14. Attach the catalytic converter to the turbocharger and tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  15. Install the power steering pump, the air conditioning compressor, and the engine cooling fan, then the accessory drive belts.
  16. If equipped with a manual transaxle, connect the backup light switch to the transaxle.
  17. connect the VSS sensor to the transaxle.
  18. Connect the heater hoses to the heater core.
  19. Attach the ground connection at the plenum chamber.
  20. Attach the heated O 2 S sensor wiring harness.
  21. If equipped with an automatic transaxle, attach the kickdown switch connector.
  22. Connect the wiring harness to the ECM.
  23. Install the ECM retaining bracket and cover the E-box.
  24. Connect the vacuum hose for the EVAP canister purge regulator valve.
  25. Connect the fuel supply and return lines.
  26. Connect the brake booster vacuum hose.
  27. The completion of the installation procedure is the reverse of the removal, keeping in mind the following items.
  28. If equipped with an automatic transaxle, check the fluid level and top off as necessary.
  29. Fill the engine with coolant and bleed as necessary
  30. 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
  31. Check the oil level before starting the engine and top off as necessary
  32. Connect the negative battery cable.
  33. Enter the radio security code.
  34. Set the clock to the correct time.

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

  1. Clear the fault codes.
  2. Adjust the headlights if necessary.
2.8L V6 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. Remove the engine undercover, and then the soundproofing material holder from the engine mount.
  3. Drain the engine coolant into a suitable container.
  4. 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.
  5. Remove the stabilizer brace from the right rear of the engine compartment.
  6. Remove the wiper arms and water deflector trim.
  7. Properly relieve the fuel system pressure.
  8. Label and detach all hoses, wiring harnesses, lines and cables as necessary for engine removal.
  9. Remove the accessory drive belt guard, then the belt.
  10. Detach the front engine mount at the crossmember.
  11. Disconnect and plug the hydraulic lines that route above the cylinder head covers from the power steering pump.
  12. Detach the ground strap from the right side engine support.
  13. Remove the air intake for the alternator.
  14. Remove the alternator and place aside and secure.
  15. 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.
  16. Unbolt the air conditioning compressor and tie it aside leaving the hoses attached.
  17. Disconnect the exhaust system from the manifolds.
  18. Disconnect the front exhaust pipes with the catalytic converters.
  19. Unbolt the starter and pull out rearward, leaving the wires attached, then secure the starter to one side.
  20. Remove the oil filter, then loosen and remove the oil cooler from under the filter.
  21. If equipped with automatic transmission, remove the flexplate-to-torque converter attaching bolts through the starter opening.
  22. Remove the engine-to-transmission mounting bolts.
  23. Position an engine support bridge tool No. 10-222A, or equivalent, to the bolted flanges of the fenders with the spindle facing forward.
  24. Attach the support adapter tool No. 3147, or equivalent, to the bolt hole above the starter mounting area in the transaxle bell housing.
  25. 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.
  26. Attach a suitable engine sling tool No. 2024A, or equivalent, to the right rear and left front of the engine.
  27. Attach an engine hoist to the sling.
  28. Lift the engine slightly.
  29. 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.
  30. Carefully pull the engine forward until it is separated from the transmission.
  31. After the engine has been separated from the transmission, lift the engine up and out of the vehicle.
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. Position the starter, and then engage the engine to the transmission.
  3. Simultaneously lower the engine and transmission into position.

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. The completion of the installation is the reverse of the removal procedure. Note the following items.
  3. Tighten the flexplate-to-torque converter mounting bolts to 63 ft. lbs. (85 Nm)
  4. 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
  5. If equipped with an automatic transaxle, check the fluid level and top off as necessary.
  6. Fill the engine with coolant and bleed as necessary
  7. 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
  8. Check the oil level before starting the engine and top off as necessary
  9. Connect the negative battery cable.
  10. Enter the radio security code.
  11. Set the clock to the correct time.

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

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

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This details will help.
Thanks.
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