Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Sling (2024 A)
• Engine/Transmission Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Hose Clip Pliers (VAS 6362)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Drip Tray for VAS 6100 (VAS 6208)
• Engine Support (T10359)
• To perform the work sequence, the ground cable must be disconnected from the battery. See if a coded radio is installed. If so, obtain the anti-theft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route all lines and wires in their original locations.
• Ensure sufficient clearance to all moving or hot components.
- Check the Diagnostic Trouble Code (DTC) memories for all the control modules. Refer to the vehicle diagnostic tester.
- Disconnect the battery ground (GND) cable with the ignition turned off.
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.
- Remove the battery, battery tray bolts - arrows - and tray.
- Remove the wiper arms.
- Remove the plenum chamber cover. Refer to one of the following:
• GTI (from 2006 through 2009), Eos and Passat.
• Tiguan and CC
• GTI (from 2010)
GTI and Eos:
- Remove the plenum chamber bulkhead.
- Disconnect the engine wiring harness connector from the Engine Control Module (ECM). Refer to one of the following:
• => [ Engine Control Module, through 11.08 ] Service and Repair.
- Remove the charge air pipe from the noise generator, if equipped. Refer to => [ Charge Air Pipe from Noise Generator ] Charge Air Pipe from Noise Generator.
Continuation for all Vehicles:
- Release the pass-through for the engine wiring harness - arrow - and pull off upward.
- Remove the E-box cover by sliding both latches in the - direction of the arrow -.
- Remove the nuts and disconnect the cable - A - for the generator and the cable - B - for the battery from the fuse holder.
- Remove the bolt - arrow - and remove the ground (GND) wire from the longitudinal member.
- Open the locking mechanisms - arrows - of the cable guide on the longitudinal member.
- Free up the electrical connector - 1 - and disconnect.
- Open the underlying wiring guide bracket - 2 -.
- Take the ECM wiring harness out of the wiring guide and lay it on the engine.
Vehicles with a Manual Transmission:
- Remove the selector mechanism from he transmission.
- Pinch off the hose leading to the brake fluid reservoir using (3094).
- Pull the clip - arrow - for the line out to the stop.
- Pull the line out of the slave cylinder and seal it off.
Do not press the clutch pedal.
Vehicles with a Automatic Transmission:
- Remove the selector lever cable from the transmission.
Vehicles with a Direct Shift Gearbox:
- Remove the selector lever cable from the transmission.
Tiguan with a Automatic Transmission:
- Remove the transmission oil cooler lines from the transmission.
Continuation for All Vehicles:
- Disconnect the connector - 2 -.
- Remove the fan shroud upper bolts - arrows -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the electrical connectors - arrow - and free up the electrical wire.
Risk of scalding due to hot steam and hot coolant.
• When the engine is warm the cooling system is under pressure.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the coolant expansion tank cap.
- Remove the noise insulation.
- Remove the front part of the wheel housing liner or the front wheel housing liner.
- Remove the charge air hoses - arrows -.
- Remove the bolt - 1 - and remove the charge air pipe downward.
- Disconnect the electrical connector - 1 - and remove the lower fan shroud bolts - arrows -.
- Remove the fan shroud downward.
- Disconnect the electrical connector - 2 - for the Engine Coolant Temperature (ECT) sensor on radiator (G83).
• Collect the leaking coolant in a clean container for disposal or reuse.
- Place (VAS 6208) under the engine.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Remove the coolant hoses - 1 and 2 -.
The fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting the connection, wrap a cloth around the connection. Then, disconnect the connection carefully to release the pressure.
- Disconnect the lines from the fuel transfer.
1) Vent line
2) Vacuum line
3) Fuel supply line
GTI, Passat, CC and Eos:
- Remove the upper coolant hose from the radiator - arrow -.
Tiguan:
- Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.
Continuation for All:
- Disconnect the coolant hoses leading to the heater core - arrows -, to do this slightly pull the securing clip.
- From above, remove the nuts - arrows - for the front exhaust pipe to the turbocharger.
- Disconnect the vacuum hoses - arrows -.
Vehicles with Front Wheel Drive (FWD):
- Remove the right drive axle heat shield bolts - arrows - and shield.
Continuation for All:
- Remove the drive axles.
- Remove the front exhaust pipe with the catalytic converter. Refer to => [ Catalytic Converter with Front Exhaust Pipe ] Exhaust System Components.
Risk of destroying due to reversed running direction of a used ribbed belt.
• Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation later.
- To release the tension on the ribbed belt, rotate the tensioner in the - direction of the arrow - from underneath.
- Secure the tensioner using (T10060 A).
- Remove the ribbed belt.
- Disconnect the Air Conditioning (A/C) compressor regulator valve (N280) - 1 - connector.
Risk of injury from refrigerant.
• The A/C refrigerant circuit must not be opened.
- Remove the A/C compressor bolts - arrows -.
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend the coolant lines and hoses.
- Tie up the compressor with the refrigerant lines attached to the longitudinal member.
GTI and Eos:
- Remove the generator (C).
Continuation for All:
- Remove the bolt - 2 - for the after-run coolant pump (V51) bracket.
• The after-run coolant pump stays in the installed position.
- Remove the bolts - 1 through 3 - and remove the pendulum support.
- Remove all remaining electrical wires necessary, from the engine/transmission and set aside.
- Disconnect all coolant and vacuum connections and intake hoses from the engine.
- Install the (T10359) to the cylinder block using bolt - 1 -, tighten the bolt to 20 Nm.
• The threaded hole for the bolt - 1 - serves to secure the after-run coolant pump.
- Install the (V.A.G 1383 A) to the (T10359).
- Slightly lift the engine and the transmission.
• Use a (VAS 5085) to remove the engine and transmission mount bolts.
- Remove the engine mount bolts - arrows -.
- Remove the transmission mount bolts - arrows -.
• Verify that all hose and line connections between the engine, transmission and body have been disconnected.
• To prevent damage, carefully guide the engine and transmission when lowering.
Vehicles with a Direct Shift Gearbox:
• Pay attention to the selector lever cable.
Continuation for All:
- Pull the engine and transmission as far as possible to the left and slowly lower it.
Secure the engine to the (VAS 6095) when working on the engine. Refer to => [ Engine, Securing to Assembly Stand ] Engine, Securing to Assembly Stand.