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Home >> Volkswagen >> 2010 >> Passat Wagon (3C5) L4-2.0L Turbo (CCTA) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine, Removing

Engine, Removing






Engine, Removing

• To perform work sequence, the Ground cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti-theft coding beforehand.

• The engine is removed downward together with the transmission.

• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.

- Check the DTC memories for all the control modules => Vehicle Tester.

- Disconnect battery Ground (GND) strap with ignition switched off.

- Remove the engine cover => [ Engine Cover, Removing and Installing ] Engine Cover, Removing and Installing.

- Remove the air filter => [ Air Filter, Removing and Installing ] Air Filter, Removing and Installing.

- Remove the battery and battery tray.





- Remove the wiper arms => Windshield Washer System; Windshield Washer System, Removing and Installing; Wiper Arms, Removing and Installing.

- Remove the plenum chamber cover => Flush Bonded Windows; Plenum Chamber Cover Assembly Overview.

Rabbit, Eos:

- Remove the plenum chamber bulkhead => Plenum Chamber Bulkhead, Assembly Overview.

- Disconnect the engine wiring harness connector from the Engine Control Module (ECM). => [ Engine Control Module, Rabbit and Eos through 02.22.2008 ].

- Remove the charge air duct to the sound generator, if equipped.

Passat:

- Disconnect the engine wiring harness connector from the Engine Control Module (ECM). => [ Engine Control Module, Passat ] Table of Contents.

Tiguan:

- Disconnect the engine wiring harness connector from the Engine Control Module (ECM). => [ Engine Control Module, Tiguan ].

All:





- Release pass-through for engine wiring harness - arrow - and pull off upward.

- Remove E-box cover by slide both latches in - direction of arrow -.





- Disconnect the cable from the generator - A - and the cable from the battery - B - on the fuse holder.





- Disconnect the Ground (GND) wire on the longitudinal member - arrow -.





- Open the locking mechanisms of the cable guide on longitudinal member - arrows -.





- Free up electrical connector - 1 - and disconnect.





- Open the underlying wiring guide bracket - 2 -.

- Take the Engine Control Module (ECM) wiring harness out of the wiring router and lay it on the engine.

1.8L vehicles with manual transmission:

- Remove the shift mechanism on the transmission => Shift Mechanism, Removing and Installing.

- Remove brace - 1 -.





- Remove slave cylinder - arrows - and set aside, do not open line system.

CAUTION!
Do not operate the clutch pedal anymore after slave cylinder has been removed. Slave cylinder may be damaged by doing this.

2.0L vehicles with manual transmission:

- Remove the shift mechanism on the transmission => Shift Mechanism, Removing and Installing.

- Pinch off the hose leading to the sensor cylinder using the Hose Clamp (3094).





- Pull the clamp - arrow - for the line up to the stop.





- Pull the line out of the ventilator/slave cylinder and seal it off.

CAUTION!
Do not operate clutch pedal any more.

Vehicles with automatic Transmission:

- Remove the selector lever cable from the transmission => Shift Mechanism, Servicing.

Vehicles equipped with DSG(R):

- Remove the selector lever cable from the transmission =>
Selector Mechanism; Selector Lever Cable, Removing and Installing.

Tiguan with automatic transmission:

- Remove the transmission oil cooler lines from the transmission=> Automatic Transmission.

All Vehicles

- Disconnect electrical connector - 2 -.





- Remove the upper mounting bolts for the air shroud - arrows -.





- Loosen the hose clamp - 2 -.





- Remove bolt - 4 -.

- Disconnect the electrical connectors - arrow - and free up the electrical wire.

CAUTION!
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 coolant reservoir cap with a cloth and carefully opening.

- Open coolant reservoir cap.

- Remove the noise insulation => Noise Insulation; Noise Insulation Assembly Overview.

- Remove the front part of the wheel housing liner and/or the front wheel housing liner => Wheel Housing Liner.

- Remove the charge air hoses - arrows -.





- Remove the bolt - 1 - and remove the air guide pipe downward.





- Disconnect the electrical connector - 1 - and remove the lower mounting screws - arrows - for the air shroud.





- Remove the air shroud downward.

- Disconnect the electrical connector - 2 - for the Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83).





• Collect escaping coolant in a clean container for disposal or reuse.

- Place drip tray (VAS 6208) under engine.

- Drain coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

- Remove coolant hoses - 1 and 2 -.





CAUTION!
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Disconnect the wires from the fuel transfer.





1) Vent line

2) Vacuum line

3) Fuel supply line

Golf, Passat, 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 on the radiator.

All:





- Disconnect the coolant hoses leading to the heat exchanger - arrows -, to do this slightly pull the securing clip.

- From above, remove the nuts - arrows - on the front exhaust pipe connection to the turbocharger.





- Disconnect the vacuum hoses - arrows -.





Vehicles with front wheel drive:





- Remove the right driveshaft heat shield - arrows -.

All:

- Remove the driveshafts => Driveshafts, Removing and Installing

- Remove the front pipe with the catalytic converter => [ Catalytic Converters with Front Exhaust Pipe, Removing and Installing ] Service and Repair.

CAUTION!
Risk of destroying due to reversed running direction on a used ribbed belt.

• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

- To release the tension on the ribbed belt, turn the tensioner in - direction of arrow - from underneath.





- Secure tensioner with Drift (T10060 A).

- Remove ribbed belt.

- Disconnect the A/C compressor regulator valve (N280) - 1 - connector.





CAUTION!
Risk of injury from refrigerant.

• The air conditioning refrigerant circuit must not be opened.

- Remove A/C compressor bolts - arrows -.

CAUTION!
Risk of damaging coolant lines and hoses.

• Do not stretch, kink or bend coolant lines and hoses.

Passat, Tiguan:

- Tie up the compressor with the refrigerant lines attached to the longitudinal member.

Rabbit, Eos:

- Remove the generator (C).

All:





- Remove the bolt - 2 - on the bracket for the After-Run Coolant Pump (V51).

• The After-Run Coolant Pump (V51) stays in the installation position.

- Remove the screws - 1 to 3 - and remove the pendulum support.





- If present, disconnect the electrical connector - 1 - for the Oil Level Thermal Sensor (G266) and remove the bracket - 2 - on the subframe.





- Remove all remaining electrical wires necessary from engine/transmission and set aside.

- Disconnect all connection-, coolant-, vacuum- and intake hoses from the engine.

- Tighten the engine bracket (T10359) to the cylinder block using the bolt - 1 - to 20 Nm.





• The threaded hole in the bolt - 1 - serves to secure the After-Run Coolant Pump (V51).

- Mount the Engine/Transmission Jack (V.A.G 1383 A) on the engine bracket (T10359).

- Slightly lift the engine and the transmission.

• Use a step ladder (VAS 5085) to remove assembly mounting bolts.

- Remove the subframe bolts - arrows - on the engine.





- Remove the subframe bolts - arrows - on the transmission.





• Verify that all hose and line connections between engine, transmission and body have been disconnected.

• To prevent damage, carefully guide the engine and transmission when lowering.

Twin clutch transmission:

• Pay attention to the selector lever cable.

All:

- Pull the engine and transmission as far as possible to the left and slowly lower it.

Secure engine on Engine and Transmission Holder (VAS 6095) when working on engine=> [ Engine, Securing on Assembly Stand ] Engine, Securing on Assembly Stand.
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