Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80-200)
• Engine Sling (2024 A)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Drip Tray for VAS 6100 (VAS 6208)
• Engine Support (T10359)
• Hose Clip Pliers (VAS 6362)
• Engine Bung Set (VAS 6122)
• To perform this procedure, 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 of all control modules before removing the engine. 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, the battery tray bolts - arrows - and tray.
- Remove the wiper arms.
- Remove the plenum chamber cover. Refer to one of the following:
GTI (2008 through 2009).
Passat
Tiguan
CC
Eos and GTI (from 2010)
GTI and Eos
- Remove the plenum chamber bulkhead.
- Disconnect the engine wiring harness connector from the Engine Control Module (ECM).
- Remove the charge air pipe from the noise generator, if equipped. Refer to => [ Charge Air Hose to Noise Generator ] Charge Air Hose to Noise Generator.
Passat and CC
- Disconnect the engine wiring harness connector from the ECM. Refer to one of the following:
=> [ Engine Control Module J623, Passat and CC through 11.10 ] Engine Control Module J623, Passat and CC through 11.10
=> [ Engine Control Module J623, GTI (from MY 2010) Eos from 11.08 and CC from 11.10 ] Engine Control Module J623, GTI (from MY 2010) Eos from 11.08 and CC from 11.10
Tiguan
- Disconnect the engine wiring harness connector from the ECM.
Continuation for All
- 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 arrows -.
- Remove the nut - A -, the cable from the generator and the cable from the battery - B - from the fuse holder.
- Remove the bolt - arrow - and ground wire from the longitudinal member.
- Open the wire guide locking mechanisms - arrows - 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 router and lay it on the engine.
with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Clamp off the hose leading to the master cylinder using the hose clamp up to 25 mm dia. (3094).
- Pull out the clip - arrow - for the hose/line assembly.
- Pull the hose/line assembly out of the slave cylinder and seal it off.
Do not press the clutch pedal.
with a Automatic Transmission
- Remove the selector lever cable from the transmission.
with a Direct Shift Gearbox (DSG(R))
- 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
- Disconnect the connector - 2 -.
- Remove the fan shroud upper bolts - upper arrows -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the connector - arrow - and free up the electrical wire.
The coolant system is under pressure when the engine is warm.
Risk of scalding due to hot steam and hot coolant.
Reduce pressure by covering the coolant expansion tank cap with a cloth and open carefully.
- Open the coolant expansion tank cap.
- Remove the noise insulation. Refer to one of the following:
GTI and Tiguan
Eos and Passat
CC
- Remove the front part of the wheel housing liner or the entire front wheel housing liner.
- Remove the charge air hoses - arrows -.
- Disconnect the connector - 1 - and remove the fan shroud lower bolts - lower arrows -.
- Remove the fan shroud downward.
- Remove the bolt - 1 - and remove the charge air pipe downward.
- Disconnect the connector - 2 - from the engine coolant temperature sensor on radiator outlet.
• Collect leaking coolant in a clean container for disposal or reuse.
- Place the drip tray for VAS 6100 (VAS 6208) under the engine.
- Drain the coolant. Refer to => [ Coolant, Draining and Filling ] Procedures.
- Remove the coolant hoses - 1 and 2 -.
The fuel supply line is under pressure. Always wear protective eye wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.
- Disconnect the lines at the bracket.
1 - Vent line
2 - Vacuum line
3 - Fuel supply line
GTI, Passat, CC and Eos
- Remove the upper coolant hose - arrow - from the radiator.
Tiguan
- Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.
Continuation for All
- Remove the bracket slightly in order to remove the heater core hoses - arrows -.
- From above, remove the front exhaust pipe to turbocharger/exhaust manifold nuts - arrows -.
- Disconnect the vacuum hoses - arrows -.
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 pipe with the catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
Risk of destroying due to a 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, turn the tensioner in the - direction of the arrow - from underneath.
- Secure the belt tensioner using the locking pin (T10060 A).
- Remove the ribbed belt.
- Disconnect the connector - 1 - from the A/C compressor regulator valve.
Refrigerant can cause serious personal injury.
• Do not open the Air Conditioning (A/C) refrigerant circuit.
- Remove the A/C compressor bolts - arrows -.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend the refrigerant lines and hoses.
- Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.
GTI and Eos
- Remove the radiator.
- Remove the generator.
Continuation for All
- Remove the after-run coolant pump bracket bolt - 2 -.
• The after-run coolant pump stays in the installed position.
- First, remove the bolt - 1 -, then the bolts - 2 and 3 - then the pendulum support.
- Disconnect any remaining electrical wires necessary from the engine/transmission and set aside.
- Disconnect all coolant, vacuum and intake hose connections from the engine.
Always use pin (T10359/2) and the tensioner from the transmission set. Otherwise the engine will tip over.
• Install the pin (T10359/2) into the engine support (T10359) and the tensioner from the transmission set.
- Attach the engine support (T10359) - 1 - to the engine and guide it into the mount.
- Seat the tensioner - 3 - in order to prevent the engine from tilting out of the engine support (T10359).
- Secure the engine support (T10359) - 1 - to the cylinder block using the bolt - 3 - and tighten it to approximately 20 Nm.
• The threaded hole for the bolt - 1 - was for the after-run coolant pump.
- Install the engine-/gearbox jack (V.A.G 1383 A) to the engine support (T10359).
- Slightly lift the engine and transmission.
• Use a step ladder (VAS 5085) to remove the engine and transmission mount to bracket bolts.
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• Verify that all hose and wire connections between the engine, transmission and body have been disconnected.
• To prevent damage, carefully guide the engine and transmission when lowering.
with a DSG(R)
• Pay attention to the selector lever cable.
Continuation for All
- Move the engine and transmission as far as possible to the left and slowly lower it.
Secure the engine onto the engine and transmission holder (VAS 6095) when working on it. Refer to => [ Engine, Securing to the Engine/Transmission Holder ] Procedures.