Engine, Removing
Engine, Removing
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.
• For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.
• Ensure sufficient clearance to all moving or hot components.
Special tools, testers and auxiliary items required
• Lifting Tackle (3033)
• Hose Clamps Up to 25 mm Dia. (3094) (vehicles with a manual transmission)
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Step Ladder (VAS 5085)
• Shop Crane - Load Cap = 700-1200 KG (VAS 6100)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Transportation Lock (T10404)
• Engine Bung Set (VAS 6122)
• Wrench SW 13 (T10384)
• Follow the safety precautions when working on the diesel direct injection system. Refer to => [ Safety Precautions ] Diesel Fuel Injection.
• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Diesel Fuel Injection.
Always follow these instructions before and during work.
• Engine and transmission mount overview. Refer to => [ Engine and Transmission Mount Overview ] Engine and Transmission Mount Overview.
• Cooling system component overview, body side. Refer to => [ Cooling System Component Overview, Body Side ] Cooling System Component Overview, Body Side.
• Fuel filter overview. Refer to => [ Fuel Filter Overview ] Fuel Filter Overview.
• Turbocharger and exhaust manifold with attachments overview. Refer to => [ Turbocharger and Exhaust Manifold with Attachments Overview ] Turbocharger and Exhaust Manifold with Attachments Overview.
• Charge air cooling system component overview. Refer to => [ Charge Air Cooler Component Overview ] Service and Repair.
• Particulate filter with NOx reduction catalytic converter overview. Refer to the following:
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
• Exhaust Gas Recirculation (EGR) system component overview. Refer to => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• Hose connections are secured with either spring type or clamp type clamps.
• Always replace clamp type clamps with spring type clamps.
• hose clip pliers (VAS 6362) or hose clip pliers (VAS 6340) are recommended for installing spring clamps.
• To perform this procedure, the battery ground cable must be disconnected. See if a coded radio is installed. If so, obtain the anti-theft code beforehand.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
• The engine is removed forward together with the transmission.
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.
• For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.
• Ensure sufficient clearance to all moving or hot components.
Requirements
• The ignition is turned off.
• The engine must be cold.
Removing
- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Refer to "Vehicle Self-Diagnosis" 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 intake tube between the Mass Airflow (MAF) sensor and intake duct. Loosen the hose clamps using hose clip pliers (VAS 6362).
Electronic components could be destroyed when the battery is disconnected:
• Follow the required steps when disconnecting the battery.
- Turn off the ignition and disconnect the ground cable - arrow - from the battery.
- Remove the battery, the battery tray bolts - arrows - and tray.
- Disconnect the connector from the Engine Control Module (ECM). Refer to one of the following:
Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10, refer to => [ Engine Control Module J623 ] Service and Repair.
Jetta from MY 11, refer to => [ Engine Control Module J623 ] Service and Repair.
- Release the engine wiring harness retainer - A - and remove it upward - arrow -.
- Remove the E-box cover by sliding both latches in the - direction of the arrows -.
- Remove the nuts and disconnect the generator wire - A - and the battery wire - B - from the fuse holder.
- Open all the cable guide locking mechanisms - arrows - on the longitudinal member.
- Disconnect the connector - arrow - from the starter.
- Remove the ground wire from the transmission bracket.
- Disconnect the connector for the exhaust gas temperature sensor 2 (- 1 -), the "black" connector for the exhaust gas temperature sensor 1 (- 2 -) and the connector for the heated oxygen sensor (- 3 -) at the plenum chamber bulkhead.
- Disconnect the exhaust gas temperature sensor 3 connector - 1 - (attached behind the bracket).
- Disconnect the connector - 2 - for the exhaust pressure sensor 1 (- 1 -).
- Remove the bolt - 4 - and bracket - 3 - with the exhaust pressure sensor 1 (- 1 -) in the - direction of the arrow - and lay them aside (the wires remain connected).
- Remove the heat shield and disconnect the connector for the exhaust pressure sensor 2. Refer to the following:
• Engine code CJAA, refer to => [ Particulate Filter with NOx Reduction Catalytic Converter Overview ] Particulate Filter with NOx Reduction Catalytic Converter Overview.
- Disconnect the wire from the exhaust pressure sensor 2. Remove the hose clamp using hose clip pliers (VAS 6362).
- Remove the bolts and bracket with the exhaust pressure sensor 2 and lay them aside (the wire to the particulate filter remains connected).
- Remove the wastegate bypass regulator valve from the retainer and lay it on the engine.
- Remove the bolt - arrow - and move the windshield washer fluid reservoir filler tube to the side.
- Remove the coolant expansion tank and lay it on the engine (the coolant hoses remain connected).
- Remove the fuel filter. Refer to => [ Fuel Filter ] Fuel Filter.
- Remove the auxiliary fuel pump. Refer to => [ Auxiliary Fuel Pump V393 (In-Line Electric Fuel Pump) ] Auxiliary Fuel Pump V393 (In-Line Electric Fuel Pump).
- Disconnect the vacuum hose from the brake booster.
- Remove the noise insulation.
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Disconnect all the coolant lines between the engine and radiator. Refer to => [ Cooling System Component Overview, Body Side ] Cooling System Component Overview, Body Side.
- Open the quick-release couplings to the heater core - arrows - at the plenum chamber bulkhead.
• Collect any leaking fluid using the drip tray for VAS 6100 (VAS 6208).
- Disconnect all the connecting hoses between the engine and charge air cooler. Refer to => [ Charge Air Cooler Component Overview ] Service and Repair.
- Extract the refrigerant from the Air Conditioning (A/C) system.
- Remove the refrigerant lines from the A/C compressor and condenser and secure them to the body without tension.
- Remove the lock carrier.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the drive axles from the transmission only.
The coupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:
• Do not bend the coupling element more than 10°.
• Do not stretch the coupling element.
• Do not damage the wire mesh on the coupling element.
• Use the transportation lock (T10404) to secure the unlocking element from over bending.
- Remove the lower bracket for the particulate filter.
- Remove the Exhaust Gas Recirculation (EGR) filter, see - item 9 - in the => [ Exhaust Gas Recirculation System Component Overview ] Service and Repair.
• Remove the nuts above the bracket using the wrench SW 13 (T10384).
- Remove the bolt - arrow - on the top bracket for the particulate filter. Loosen the bracket on the cylinder head.
- Loosen the clamp - 1 - between the particulate filter and the turbocharger.
- Secure the particulate filter to the body without tension.
with a Manual Transmission
- Remove the shift mechanism from the transmission.
- Pinch off the hose leading to the master cylinder using a hose clamp up to 25 mm dia. (3094).
- Pull the clip - arrow - for the hydraulic clutch hydraulic line - A - out until it stops.
- Remove the hydraulic line - A - from the breather/slave cylinder and seal it off.
Do not operate the clutch pedal any more.
with a Direct Shift Gearbox (DSG(R))
- Disconnect the selector lever cable from the transmission.
Continuation for All
- Disconnect all necessary remaining electrical wires from the engine and transmission and set aside.
• Verify that all hose and wire connections between the engine, transmission and body have been disconnected.
- Remove the pendulum support bolts - 1 through 3 -.
- Install the lifting tackle (3033) as follows and support the engine/transmission subassembly using the shop crane - load cap = 700-1200 KG (VAS 6100).
Vibration damper side:
• Position 2.
Flywheel side:
• Position 8.
- Remove the engine mount to engine mount bracket bolts - arrows -.
with a Manual Transmission
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
with a DSG(R)
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
Continuation for All
• When removing the engine/transmission subassembly, guide it out carefully to avoid damaging it.
- Raise the engine/transmission subassembly slightly and remove it toward the front.
- Separate the transmission from the engine. Refer to => [ Transmission and Engine, Separating and Assembling ] Engine and Transmission, Separating and Assembling.
Secure the engine to the engine and transmission holder (VAS 6095) when working on it. Refer to => [ Engine, Securing to ] Procedures.