Tdi 2.0 bkd engine replacement/removal - swap like fir like.

[mikk@]

Hi folks.

As title states, im trying to get details on the easiest method to remove and replace a bkd 2.0tdi like for like.
Got a donor car for cheap and looking tko swap engine and gearbox together.
My current package is getting long in the tooth and is due for clutch, belt, turbo etc - donor car is low kms stat writeoff.

Options :
1 front end removal
2. Drop engine and gearbox together
3. Drop complete engine, gearbox, suspension, subframe complete.
Any help would be HIGHLY appreciated.

Ps. Searches have not been very successful on tis process.
Mikk

[GTI4ME]

If you're only swapping the motor and box, then for me I would be removing the bumper/radiator support panel with the rad/cooler/condenser still attached, then drop off all the connections to the motor and box and pull them out as a unit. In perfect world it's a day job at most, half day job if everything goes your way.
*edit: just be mindful of a/c gas! the system would need to be drained before removing the front end. PM me if you need any extra info.

[mikk@]

Id be stoked if i got away with doing it in a day!!
Was thinking if i can do the combination of front clip removal with engine,gearbox,suspensions,steering etc would be best as donor car components hasve lower kms than current components.

[Umai Naa!!]

If you had access to a hoist, you could drop the whole lot out the bottom in 2-3hours.

Only fluid you'd lose is coolant.

Only suspension/steering stuff that comes out is the front driveshafts and front subframe, with the swaybar and LCAs still attached to it. With the subframe still in the car, undo the 4 (3, if it's a later one) bolts for the rack, and leave that in the car. The subframe, etc needs to come out first anyway, before the motor and box can come out the bottom.

Wiring is pretty easy to sort out, too. Unclip it at the ECU, pull it through the top of the plenum and drape it over the motor, then it's just the power feeds to the alternator and starter motor, a couple of earths, and a couple of connectors on the left side chassis rail.

Also, unbolt the A/C compressor from the motor, and tie it up under the radiator with the lines still attached. No loss of gas.

** I would only ever pull the front off if you couldn't get the car high enough to get the motor/gearbox out the bottom. It's a fiddly process that will add a good half a day removing and re-fitting.

[mikk@]

If you had access to a hoist, you could drop the whole lot out the bottom in 2-3hours.

Only fluid you'd lose is coolant.

Only suspension/steering stuff that comes out is the front driveshafts and front subframe, with the swaybar and LCAs still attached to it. With the subframe still in the car, undo the 4 (3, if it's a later one) bolts for the rack, and leave that in the car. The subframe, etc needs to come out first anyway, before the motor and box can come out the bottom.

Wiring is pretty easy to sort out, too. Unclip it at the ECU, pull it through the top of the plenum and drape it over the motor, then it's just the power feeds to the alternator and starter motor, a couple of earths, and a couple of connectors on the left side chassis rail.

Also, unbolt the A/C compressor from the motor, and tie it up under the radiator with the lines still attached. No loss of gas.

** I would only ever pull the front off if you couldn't get the car high enough to get the motor/gearbox out the bottom. It's a fiddly process that will add a good half a day removing and re-fitting.

Cheers!
Ill take ur advice and use the worshop hoist to drop the lot in one go.
Is there anything on th interweb i can direct the mechanic to lookup before we get cracking?

[Umai Naa!!]

Not off the top of my head.

If you go by the factory workshop manual, you'll be still doing it a month later. Plus it mentions a lot of workshop tools that either aren't necessary, are unavailable, or can be substituted for common sense.