Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Hack (V.A.G 1383 A)
• Spring Type Clip Pliers (VAS 5024A)
• Step Ladder (VAS 5085)
• Engine/Transmission Support (T10012)
• Hose Clamp Up to 25 mm Dia. (3094)
• Cable Tie
For information on securing the engine to the engine stand, refer to => [ Engine, Securing to Assembly Stand ] Engine, Securing to Assembly Stand.
• To perform this procedure, the ground cable must be disconnected from 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.
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 (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.
- Disconnect the battery Ground (GND) cable with the ignition turned off.
- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.
- Remove the battery, the battery tray bolts - arrow - and tray.
GTI and Eos
- Remove the wiper arms and the plenum chamber cover.
- Remove the bulkhead plenum chamber.
- Disconnect the engine wiring harness connector from the Engine Control Module (ECM).
- Disengage the pass through for the engine wiring harness - arrow - and remove upward.
Passat
- Remove the windshield wiper arms.
- Remove the plenum chamber cover.
- Disconnect the engine wiring harness connector from the ECM.
- Disengage the pass through for the engine wiring harness - arrow - and remove upward.
Continuation for All Vehicles
- Remove the nut and generator cable - arrow - from the fuse holder.
- Remove the bolt and ground wire - arrow - from the longitudinal member.
- Open the cable guide locking mechanisms - arrows - on the longitudinal member.
- Disconnect all harness connectors for the engine wiring harness/body and set the engine wiring harness on the engine.
CAUTION!
The fuel system is under pressure!
• Wear protective goggles and protective clothing to prevent injuries and contact with skin.
• Before disconnecting the connections, place a cloth around the connection point. Then release pressure by carefully disconnecting the lines.
- Disconnect the lines - 1, 2 and 3 -. To do so, press the release buttons.
GTI and Eos
- Disconnect the ventilation hoses - arrows 1 and 2 -. Remove the Evaporative Emission (EVAP) canister - A - with vent hoses upward from the bracket.
Continuation for All Vehicles
- Remove the noise insulation
- Remove the front parts of the left and right wheel housing liners.
- Disconnect the charge air hoses - arrows -.
- Remove the drive axle heat shield bolts - arrows - and shield.
- Remove the right and left drive axles.
- Remove the exhaust pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Bring the lock carrier into service position. Radiator Support
- Drain the coolant. Refer to => [ Draining and Filling ] Draining and Filling.
- Evacuate the Air Conditioning (A/C) system.
- Remove the A/C line bolt - arrow - and line from the compressor.
- Remove the refrigerant line bolt - arrow - and line from the condenser.
- Remove the bolts - 1 through 3 - and remove the pendulum support.
- Remove all remaining electrical wires necessary from the engine/transmission and set aside.
- Disconnect all coolant, vacuum, and intake hose connections from the engine.
With a Manual Transmission
- Remove the selector mechanism from the transmission.
- Clamp off the hose/line assembly hose - A - to the slave cylinder using (3094).
- Pull the hose/line assembly clip - arrow - out as far as far as the stop.
- Remove the hose/line assembly from the slave cylinder breather.
CAUTION!
Do not operate the clutch pedal any more.
With a Automatic Transmission
- Disconnect the shift lever cable from the transmission.
With a Direct Shift Gearbox(R)
- Disconnect the selector lever cable from the transmission.
Continuation for All Vehicles
- Remove the auxiliary coolant pump bolts - arrows -.
- Install the (T10012) to the (V.A.G 1383 A).
- Install the (T10012) to the engine as shown and tighten the bolt - 1 - and nut - 2 - to approximately 20 Nm.
- Gently lift the engine and transmission using (V.A.G 1383 A).
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• Use (VAS 5085) to remove the bolts.
• Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.
- Carefully lower the engine with transmission.