Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Tension Strap (T10038)
• Locking Pin (T10060 A)
• Engine Support (T10359)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine-/Gearbox Jack (V.A.G 1383 A)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Drip Tray for VAS 6100 (VAS 6208) or (V.A.G 1306)
• Hose Clip Pliers (VAS 6362)
• Cable Tie
• To perform this procedure, the battery ground cable must be disconnected from the battery. Check whether 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.
• Seal off removed fuel, ventilation and vacuum lines so no dirt enters the system.
• Leave the key in the ignition lock to prevent the steering wheel from locking.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Refer to On Board Diagnostic (OBD) in the vehicle diagnostic tester.
- 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 and the battery tray.
Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09:
- Remove the charge air pipe from the noise generator, if equipped.
- Disconnect the engine harness connector from the Engine Control Module (ECM).
- Release the pass-through for the engine 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 the wire from the generator - A - and the wire from the battery - B - from the fuse holder.
- Open all 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 -.
- Remove the ECM wiring harness out of the wiring router and lay it on the engine.
GLI from MY 12:
- Remove the E-box cover - arrows - inside the engine compartment.
- Remove the nut and the wire - 2 - and free it up.
- Disconnect the connector - 1 - from the ECM and free up the engine harness. Refer to => [ Engine Control Module ] Service and Repair.
Vehicles with a Manual Transmission:
- Remove the shift mechanism from the transmission.
- Use hose clamps up to 25 mm dia. (3094) to pinch off the hose leading to the clutch master cylinder.
- Pull the clip - arrow - for the line - A - out, up to the stop.
- Disconnect the line - A - from slave cylinder breather and seal it off.
Do not operate the clutch pedal any more.
Vehicles with Direct Shift Gearbox (DSG):
- Disconnect the selector lever cable from the transmission.
Continuation for all Vehicles:
- Remove the bolt and the ground wire - arrow - from the longitudinal member.
- Disconnect the connector - 2 -.
- Remove the fan shroud upper bolts - upper arrows -.
- Loosen the hose clamp - 2 -.
- Remove the bolt - 4 -.
- Disconnect the electrical connector - arrow - and free up the electrical wire.
Risk of scalding due to hot steam and hot coolant:
• The coolant system is under pressure when the engine is warm.
• Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
• Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.
- Open the cap on the coolant expansion tank.
- Remove the front wheels.
- Remove the noise insulation.
- Remove the front part of the wheel housing liners and/or the front wheel housing liners.
- 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 - lower arrows -.
- Remove the fan shroud downward.
- Disconnect the connector - 2 - from 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) or (V.A.G 1306) under the engine.
- Drain the coolant. Refer to => [ Draining and Filling ] Service and Repair.
- Reposition the clamps - 1 and 2 - and disconnect the coolant hoses.
The fuel system is under pressure!
• Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect the lines and catch any fuel coming out with a cloth.
1. Ventilation line (press the circlip to release the line).
2. Vacuum line (press the circlip to release the line), if equipped.
3. Fuel supply line (pull the circlip upward to release the line).
- Remove the upper coolant hose - arrow - from the radiator by removing the securing clip.
- Disconnect the heater core coolant hoses - arrows -.
- From the top, remove the front exhaust pipe with catalytic converter to turbocharger nuts - arrows -.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the drive axles.
- Remove the front exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Disconnect the solenoid clutch electrical connector - 1 - from the A/C compressor.
Risk of injury from refrigerant:
• Do not open the A/C refrigerant circuit.
- Remove the A/C compressor bolts - arrows -.
Risk of damaging the refrigerant lines and hoses:
• Do not stretch, kink or bend the refrigerant lines and hoses.
- Tie up the compressor with the refrigerant lines attached to the longitudinal member.
- Remove the generator (C).
- Remove the after-run coolant pump bracket bolt - 2 -.
• The after-run coolant pump stays in the installed position.
- First, remove the pendulum support bolt - 1 -.
- Then, remove the bolts - 2 and 3 - and remove the pendulum support.
- Disconnect the vacuum hoses - arrows -.
- Disconnect all remaining electrical wires necessary from the engine/transmission and set them aside.
- Disconnect all coolant, vacuum and intake connections from the engine.
- Install the engine support (T10359) to the cylinder block using the bolt - 1 - and tighten it to approximately 20 Nm.
• The threaded hole for the bolt - 1 - secures the after-run coolant pump.
- Install the engine-/gearbox jack (V.A.G 1383 A) to the engine support (T10359).
- Slightly lift the engine/transmission assembly.
• Use the step ladder (VAS 5085) to remove the engine/transmission mount bolts.
- Remove the engine mount to engine mount bracket bolts - arrows -.
Vehicles with a Manual Transmission:
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
Vehicles with DSG:
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
Continuation for all Vehicles:
• Verify that all hoses and lines between the engine, transmission and body have been disconnected.
• While lowering, carefully guide the engine/transmission assembly in order to prevent damages.
Vehicles with DSG:
- Pay attention to the selector lever cable.
Continuation for all Vehicles:
- Pull the engine/transmission as far as possible to the front and left and slowly lower it.
Secure the engine to the engine/transmission holder (VAS 6095) whenever working on it; refer to => [ Engine, Securing to the ] Procedures.