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 this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, 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, 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), 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 (J623), GTI (2008 through 2009) and Eos through 11.08 ] .
• => [ Engine Control Module (J623), GTI (from 2010) and Eos from 12.08 ] Engine Control Module (J623), GTI (from 2010) and Eos from 12.08.
- Remove the charge air pipe from the noise generator, if equipped. Refer to => [ Charge Air Pipe to Noise Generator ] Charge Air Pipe to Noise Generator.
Passat and CC:
- Disconnect the engine wiring harness connector from the ECM.
Tiguan:
- Disconnect the engine wiring harness connector from the ECM.
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 arrows -.
- Remove the nuts and the cable for the generator - A - and the cable for the battery - B - from the fuse holder.
- Remove the bolt and the Ground (GND) cable - arrow - from the longitudinal member.
- Open the wire guide locking mechanisms - arrows - on the longitudinal member.
- Free up the electrical connector - 1 - and disconnect it.
- Open the underlying wiring guide bracket - 2 -.
- Take the ECM wiring harness out of the wiring router and lay it on the engine.
Vehicles with a Manual Transmission:
- Remove the shift mechanism from the transmission.
- Pinch off the hose from the master cylinder using the hose clamps up to 25 mm dia. (3094).
- Pull out the clip - arrow - for the line up to the stop.
- Pull the line out of the breather/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 upper bolts - upper arrows - from the fan shroud.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the electrical 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.
- Remove the front part of the wheel housing liner or the entire 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 bolts - lower arrows - for the fan shroud.
- Remove the fan shroud downward.
- Disconnect the electrical connector - 2 - for the engine coolant temperature sensor on radiator (G83).
• Collect the 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 => [ Draining and Filling ] Procedures.
- Remove coolant hoses - 1 and 2 -.
The fuel supply line is under pressure. Always wear protective eyewear 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 from the fuel transfer.
1) Vent line
2) Vacuum line
3) Fuel supply line
GTI, Eos, Passat and CC:
- 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 Vehicles:
- 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 Vehicles:
- Remove the drive axles.
- Remove the front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converters ] Front Exhaust Pipe with Catalytic Converters.
Risk of destroying due to a reversed running direction on 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 belt tensioner in the - direction of the arrow - from underneath.
- Secure the tensioner using the locking pin (T10060 A).
- Remove the ribbed belt.
- Disconnect the A/C compressor regulator valve (N280) - 1 - connector.
Refrigerant can cause serious personal injury.
• Do not open the air conditioning refrigerant circuit.
- Remove the Air Conditioning (A/C) compressor bolts - arrows -.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant 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 Vehicles:
- Remove the after-run coolant pump bracket bolt - 2 -.
• The after-run coolant pump (V51) stays in the installed position.
- First, remove the bolt - 1 - then bolts - 2 and 3 - and then remove the pendulum support.
- Disconnect all remaining electrical wires necessary from the engine/transmission and set aside.
- Disconnect all coolant, vacuum and intake hose connections from the engine.
- Install the engine support (T10359) to the cylinder block using the bolt - 1 - and tighten the bolt to 20 Nm.
• The threaded hole for the bolt - 1 - serves to secure the after-run coolant pump (V51).
- Install the engine/transmission jack (V.A.G 1383 A) to the engine support (T10359).
- Slightly lift the engine and transmission.
• Use the step ladder (VAS 5085) to remove the engine/transmission mount 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 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 Vehicles:
- Pull the engine and transmission as far as possible to the left and slowly lower it.
Secure the engine to the engine and transmission holder (VAS 6095) when working on it. Refer to => [ Engine, Securing to ] Procedures.