Engine, Removing

WARNING: This page is about a different car, the 2008 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Lifting tackle 3033
Engine support T40074
Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Engine and transmission jack VAG 1383A
Step ladder VAS 5085
Spring type clip pliers VAS 5024A
Engine and transmission holder VAS 6095 with engine support 3269
Shop crane VAS 6100
Drip tray VAG 1306 or drip tray for VAS 6100 VAS 6208
Parts trolley VAG 1698
Engine bung set VAS 6122

The engine and transmission are removed downward.

-- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Go to "Guided Fault Finding".

NOTE:

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

Leave the vehicle key in the ignition to prevent the steering wheel lock from locking.

It is advisable to remove the front wheels before removing the engine/transmission. The vehicle can be lowered on the hoist until the cover plates for the brake discs are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment.

When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing the engine.

To prevent damage to the removed components, use the VAG 1698 for storage.

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 or vacuum) and electrical wires 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.

-- With the ignition off, disconnect the battery ground cable. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Completely remove the air filter and connecting hose. Refer to AIR FILTER ASSEMBLY OVERVIEW .

-- Remove the air filter bracket.

-- Remove the windshield wiper arms and plenum chamber cover. Refer to WIPER ARMS , and PLENUM CHAMBER COVER .

-- Loosen the bolts -arrows- for the plenum chamber bulkhead -1- and remove it together with the resonance tube -2-.

Fig 1: Loosening Mounting Bolts From Plenum Chamber Bulkhead

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the protective housing from the Engine Control Module (ECM). Refer to ENGINE CONTROL MODULE WITH ANTI-THEFT IMMOBILIZER .

-- Disconnect the engine wiring harness electrical connector from the ECM.

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

Fig 2: Identifying Pass-Through For Engine Wiring Harness

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut -arrow- and remove the wire for the generator from the fuse holder.

Fig 3: Generator Wire At Fuse Holder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the ground cable bolt -arrow- from the longitudinal member.

Fig 4: Ground (GND) Cable On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 5: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect all harness connectors for the engine harness to the body harness and set the engine harness on the engine.

WARNING:

Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.

-- Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

-- Disconnect the fuel supply line -4- and catch any leaking fuel with a cloth.

Fig 6: Identifying Fuel Supply Line, Vent Line & Vacuum Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the vent line -2- and vacuum line -3-.

NOTE:

Press in the securing ring to disengage the fuel line.

-- Seal the lines so that the fuel system is not contaminated by dirt etc.

-- Disconnect the Heated Oxygen Sensor (HO2S) electrical connectors -1 and 2- at the bulkhead and free up the wires.

Fig 7: Disconnecting Electrical Connectors And For Heated Oxygen Sensor (HO2S) G39 And Heated Oxygen Sensor (HO2S) 2 G108

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 -

HO2S 2, 6 pin connector (brown)

2 -

HO2S, 6 pin connector (black)

-- Disconnect any remaining electrical wires from the engine/transmission and set aside.

-- Remove the brake booster vacuum hose from the intake manifold.

-- Disconnect all other connections - vacuum and intake hoses from the engine.

-- Remove the shift mechanism from the transmission. Refer to (Through 02.09) SELECTOR MECHANISM OVERVIEW, THROUGH 02.09 , or (From 03.09) SELECTOR MECHANISM OVERVIEW, FROM 03.09 .

WARNING:

Hot steam may escape when opening the expansion tank cap. Wear protective goggles and protective clothing to prevent damage to your eyes and from scalding. Cover the cap with a cloth and open the cap very carefully.

-- Open and close the cap on the expansion tank, to relieve the cooling system pressure.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the front sections of the wheel housing liners. Refer to FRONT WHEEL HOUSING LINER .

-- Bring the lock carrier into the service position. Refer to Description and Operation .

-- Disconnect the wire bracket for the oil level thermal sensor at the subframe.

-- Remove the front exhaust pipe with catalytic converters. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS .

NOTE:

Do not bend the flex joints in front of the exhaust pipes 20 degrees or they could be damaged. A second mechanic is required for the removal.

-- Remove the front driveshaft tube. Refer to REMOVAL AND INSTALLATION .

NOTE:

To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate removal and installation of the engine without having to open the refrigerant circuit:

-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Open the refrigerant line fasteners on the body.

-- Remove the Air Conditioning (A/C) compressor with connected refrigerant lines from the accessory bracket. Refer to [For engine(s) BGP, BPY, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Disengage the A/C compressor -A- at the lock carrier as shown (fasteners -1 and 2-.

Fig 8: Disengaging A/C Compressor At Lock Carrier

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right drive axle heat shield.

-- Remove the drive axles. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] [For engine(s) BGP, BPY, AWP, BGQ, CBTA, CBUA, CCTA, CBFA] Removal and Installation .

-- Remove the pendulum support bolts -1 through 3- and remove the pendulum support.

Fig 9: Identifying Pendulum Support & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Disconnect the coolant hose quick release couplings from the radiator and heat exchanger.

-- Remove coolant hoses to the expansion tank.

-- Install the T40074 to the VAG 1383A.

-- Remove the T40074/1 from the T40074 and install it to the cylinder block using a nut -1-.

Fig 10: Identifying Installation Of Adapter T40074/1 To Cylinder Block

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the T40074 on the engine as shown and install the T40074/1 to the T40074 -2-.

Fig 11: Attaching Adapter T40074/1 To Cylinder Block With Nut And Securing To Engine Support T40074 With Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the T40074 with M10 x 25 bolts -arrows- to the exhaust side of the cylinder block as shown and tighten to approximately 20 Nm.

Fig 12: Identifying Bolts Of Engine Support T40074

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Gently lift the engine and transmission using the VAG 1383A.

-- Remove the engine mount to engine mount bracket bolts -arrows-.

Fig 13: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Fig 14: Identifying Transmission Mount To Transmission Mount Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Use the VAS 5085 to remove the bolts.

Carefully guide the engine and transmission, when lowering, to prevent damage to the body.

-- Carefully lower the engine and transmission.