1.2 TDI CR engine (EA189) · Removing and installing engine · Removing and installing engine

Removing engine

Special tools and workshop equipment required

  • Hose clamps to 25 mm - 3094-
  • Torque wrench - V.A.G 1331-
  • Torque wrench - V.A.G 1332-
  • Engine and gearbox jack - V.A.G 1383 A-
  • Stepladder - VAS 5085-
  • Engine support - T40076-
  • Torque wrench - V.A.G 1332-
  • Drip tray for workshop hoist - VAS 6208-
  • Hose clamp pliers - VAS 6340-
  • Gearbox support - T10412-
  • Grease (vehicles with manual gearbox) - G 000 100-
  • Cable tie

Transportation lock - T10403-

Engine bung set - VAS 6122- (not shown)

»Carry out the following work sequence«

Removing

  • Remove engine cover panel ⇒ 3 Engine cover panel.
  • With ignition switched off, disconnect battery earth strap. ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting batteries.
  • Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27; Removing and installing battery.
  • Remove air filter.
  • Drain coolant ⇒ 19 – Cooling.

Vehicles with air conditioning system

  • Extract refrigerant ⇒ Rep. gr. 87.

Continued for all vehicles

  • Remove lock carrier ⇒ General body repairs, exterior; Rep. gr. 50.
  • Unscrew positive cable -1- from battery positive distributor.
  • Lay cable down on engine during further work sequence.

Vehicles with air conditioning system

  • Remove AC compressor ⇒ Rep. gr. 87; Removing and installing air conditioner compressor.

Continued for all vehicles

  • Remove starter ⇒ Electrical system; Rep. gr. 27; Removing and installing starter.
  • Remove vacuum hose between vacuum pump and brake servo.
  • Detach vacuum line -arrow- on brake servo.

Pre-heater line -arrow 2- is not necessarily installed.

  • Disconnect connectors -1 … 4-.
  • -1- Exhaust gas temperature sender 1 - G235-
  • -2- Exhaust gas temperature sender 3 - G495-
  • -3- Exhaust gas temperature sender 4 - G648-
  • -4- lambda probe - G39-
  • Guide lines out of brackets on plenum chamber bulkhead and on turbocharger.
  • Separate electrical connector -2- on pressure differential sender - G505-.
  • Unscrew bolt -3- from pressure differential sender - G505- bracket.
  • Lay pressure differential sender - G505- with lines down to rear.
  • Unscrew coolant return line bolts -arrows-.
  • Lay coolant return line to side.
  • Remove fuel supply line and return line -arrows- at high-pressure pump.
  • Disconnect connecting hose -2- from cylinder head cover.
  • Unscrew bolt -3- (attached), turn intake hose clockwise out of its bracket and remove.
  • Remove engine control unit from its bracket ⇒ 9 Engine control unit.
  • Release engine wiring harness connector from engine control unit and remove.
  • Disconnect connector -arrow-.
  • Carefully loosen engine wiring harness at its fastening points -arrows-.
  • Place engine wiring harness on engine.
  • Separate all remaining connectors to engine.
  • Loosen particulate filter.
1)Remove securing clamp between particulate filter and turbocharger
2)Unscrew bolts -2 … 3-
3)Loosen bolt -4-
4)Unscrew nuts -5-
  • Push particulate filter aside and secure on plenum chamber bulkhead by suitable means.
  • Unscrew securing bolts -arrows- for pendulum support.
  • Unscrew bolt -2-.
  • Install gearbox support - T10412-.

The -arrow- on gearbox support points forwards.

  • Tighten securing bolts -arrows- hand tight.
  • Disconnect quick-release couplings for heat exchanger -arrows- on plenum chamber bulkhead.
  • Unscrew bolts -arrows- on engine mounting approx. 2 turns.
  • Seal open lines and unions with clean plugs from engine sealing plug set - VAS 6122-.
  • Open fasteners -arrows- and remove noise insulation -1- for sump.
  • Remove heat shield for right drive shaft -1-.
  • Unscrew all remaining securing bolts for engine to gearbox.

-5- Small cover plate for flywheel

Item -A-: dowel sleeves for centring

  • Unscrew bolt -6-.
  • During further procedure, engine bracket - T40076- is secured with a longer bolt -6-.
  • Screw engine support - T40076- with nut -1- to cylinder block to approx. 20 Nm.
  • Fit M12 nut -3- between engine bracket - T40076- and cylinder block.
  • Secure engine bracket - T40076- with M10 × 50 nut -2- on cylinder block.
  • Fit engine and gearbox jack - V.A.G 1383 A- to engine support - T40076-.
  • Insert engine bracket - T40076- in engine and gearbox jack - V.A.G 1383/A-.
  • Raise engine/gearbox assembly slightly.
  • Completely unscrew securing bolts -arrows- for engine mounting.
  • Remove entire engine mounting upwards.
  • Pull engine out of gearbox.
  • Then swivel engine forwards and lower.