LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Volkswagen >> 2009 >> Routan S >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 7 (4.0L - Engine Assembly - Engine Code: CGVA) >> 10 Engine Assembly >> Removal And Installation >> Engine, Removing
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required 

NOTE: Capture and store any residual fluid drainage, or leakage from ancillary components, in the appropriately marked containers.
Fig 1: Engine Cover
GWWUS62781Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine cover (1).

-- Release the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .

Fig 2: Identifying Positive And Negative Battery Cables
GWWUS62783Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the positive (1) and negative (3) battery cables. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 3: Identifying Wiring Harness Retainer And Battery Tray
GWWUS62785Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness retainer (2), from the battery tray.

-- Remove the battery tray bolts, and remove the battery tray (1).

Fig 4: Identifying Coolant Overflow Hose And Coolant Recovery Reservoir
GWWUS62787Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the coolant overflow hose (1) at the radiator fill cap, and remove the coolant recovery reservoir (2).

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

Fig 5: Identifying Air Filter Housing
GWWUS62789Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the air filter housing (6). Refer to AIR CLEANER HOUSING .

Fig 6: Identifying Wiring Harness Electrical Connectors
GWWUS62791Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connectors (1 and 2) from the cooling fans.

Fig 7: Identifying Left And Right Cooling Fan Clips
GWWUS62793Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the left (1) and right (2) cooling fan clips, and remove the cooling fan assembly.

Fig 8: Drive Belt Tensioner Lug & Accessory Drive Belt
GWWUS62795Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the accessory drive belt (1). Refer to ACCESSORY DRIVE BELT .

Fig 9: Identifying Generator
GWWUS62797Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the generator (1). Refer to Removing .

Fig 10: Identifying Power Steering Line Bracket Bolts
GWWUS62799Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the power steering line bracket bolts (1 and 2).

Fig 11: Identifying Evaporative Emission Purge Solenoid Wiring Harness Electrical Connector And Air Conditioning Pressure Transducer Wiring Harness Electrical Connector
GWWUS62801Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

Fig 12: Identifying Wiring Harness Electrical Connector
GWWUS62803Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (1) from the power steering pump.

Fig 13: Identifying Power Steering Pump And Bolts
GWWUS62805Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the power steering pump bolts (3) and reposition the power steering pump (2).

Fig 14: Identifying Wiring Harness Electrical Connector
GWWUS62803Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator lower hose (2) clamp at the engine.

-- Remove the radiator lower hose (2) from the engine.

Fig 15: Identifying Fuel Supply Line Quick Connect Fitting And Fuel Rail
GWWUS62809Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel supply line quick connect fitting (1) from the fuel rail (2). Refer to QUICK CONNECT FITTING DISCONNECTING AND CONNECTING .

Fig 16: Identifying EVAP Purge Line And Brake Booster Vacuum Hose
GWWUS1033802Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the EVAP purge line (1) and brake booster vacuum hose (2) from the upper intake manifold.

Fig 17: Identifying Radiator Upper Hose
GWWUS1033889Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator upper hose (1) clamp at the engine.

-- Remove the radiator upper hose (1) from the engine.

Fig 18: Identifying Wiring Harness Electrical Connectors
GWWUS62815Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

Fig 19: Identifying Wiring Harness Electrical Connector And Ground Strap Bolt
GWWUS62817Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (1) from the transmission.

Fig 20: Identifying Wiring Harness Retainer
GWWUS62839Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the wiring harness retainer (1) from the transmission shift bracket.

Fig 21: Identifying Transfer Shaft Speed Sensor Wiring Harness Electrical Connector And Output Speed Sensor Wiring Harness Electrical Connector
GWWUS62819Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

-- Disconnect the wiring harness electrical connectors from the bank 2 sensor 1 and bank 2 sensor 2 O2 sensors.

Fig 22: Identifying Rear Engine Mount Bracket Bolts
GWWUS62835Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the rear engine mount bracket bolts (1).

Fig 23: Identifying Heater And Power Steering Hose Bracket Bolts
GWWUS62841Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the heater and power steering hose bracket bolts (2) from the left engine mount and transmission bellhousing.

Fig 24: Identifying Front Heater Line Bracket Retainer Bolt
GWWUS62843Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front heater line bracket retainer bolt (1).

Fig 25: Identifying Heater Hoses
GWWUS1034275Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the heater hoses (1) and (2). Refer to QUICK CONNECT FITTING DISCONNECTING AND CONNECTING .

Fig 26: Identifying Oil Cooler Lines
GWWUS62845Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the oil cooler lines (1) from the transmission using disconnect tool 8875A.

Fig 27: Identifying Shift Cable And Transaxle Manual Valve Lever
GWWUS62847Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the shift cable from the bracket.

-- Disconnect the shift cable (1) from the transaxle manual valve lever (2).

Fig 28: Identifying Wiring Harness Electrical Connector And Ground Strap Bolt
GWWUS62817Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front wheels and tires. Refer to Removal and Installation .

-- Remove the oil filter/oil cooler splash shield and the left front wheelhouse liner. Refer to Removal and Installation .

-- Remove the ground strap bolt (2) and reposition the ground strap.

Fig 29: Identifying Wiring Harness Electrical Connector And Inline Harness
GWWUS1034435Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (2) and the inline harness (2) connector from the powertrain control module.

Fig 30: Identifying Radiator Lower Hose
GWWUS1034470Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator lower hose (1) clamp at the radiator.

-- Remove the radiator lower hose (1) from the radiator.

Fig 31: Identifying Wire Harness Electrical Connector
GWWUS1034480Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wire harness electrical connector (1) from the oil pressure sensor.

Fig 32: Identifying Engine Oil Cooler Line And Engine Oil Cooler
GWWUS62823Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the engine oil cooler line (7) from the engine oil cooler (3).

Fig 33: Identifying Bolt And Nuts
GWWUS62807Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector from the air conditioning compressor clutch coil.

-- Remove the bolt (2) and two nuts (3) from the A/C compressor and reposition the A/C compressor.

Fig 34: Identifying Oil Dipstick Tube Bolt
GWWUS62851Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the oil dipstick tube bolt (1), and remove the oil dipstick tube.

-- Remove the left (front) exhaust manifold. Refer to LEFT EXHAUST MANIFOLD .

Fig 35: Battery Cable Nut, Battery Cable, Starter Solenoid Stud & Electrical Connector
GWWUS59549Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the battery cable nut (3) and battery cable (2) from the starter solenoid stud (1).

-- Disconnect the wiring harness electrical connector (4) from the starter solenoid.

Fig 36: Identifying Front Engine Mount Through Bolt
GWWUS62831Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front engine mount through bolt (1).

Fig 37: Identifying Crossmember And Bolts
GWWUS62837Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the crossmember bolts (1 and 2).

-- Remove the crossmember (3).

Fig 38: Identifying Crossunder Pipe Bracket Bolts And Bracket
GWWUS62825Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the crossunder pipe. Refer to EXHAUST CROSSUNDER PIPE .

-- Remove the crossunder pipe bracket bolts (2) and bracket (4) from the bottom of the transmission (1).

Fig 39: Identifying Torque Converter Access Cover Bolt And Cover
GWWUS62827Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the torque converter access cover bolt (3) and cover (2).

Fig 40: Identifying Flexplate Bolt And Transmission Lower Bolts
GWWUS62829Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE: Upon removing the flexplate bolts (1), some flexplates will have a tight tolerance (slotted) bolt hole. If present, mark this location (on the bolt, flexplate and the converter) with a paint mark for realignment during installation.

-- Remove the torque converter to flexplate bolts (1).

-- Remove the transmission lower bolts (2).

Fig 41: Identifying Front Engine Mount Bracket
GWWUS1035242Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the three front engine mount bracket bolts (1) and the bracket (2).

-- Remove the muffler. Refer to MUFFLER/RESONATOR ASSEMBLY .

-- Remove the right (rear) exhaust manifold. Refer to RIGHT EXHAUST MANIFOLD .

Fig 42: Identifying Engine Mount Heat Shield With Bolts
GWWUS62833Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine mount heat shield bolts (1) and heat shield (2).

-- Remove the rear engine mount through bolt (3).

Fig 43: Identifying Left And Right Drive Axles
GWWUS57653Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left and right drive axles (1). Refer to Removal and Installation .

Fig 44: Identifying Adapter Pins 6909A, Engine Support Brackets 8130, Engine Adapters 10107, Powertrain Support Posts J-48839 And Scissor Lift Table VAS 6131
GWWUS62853Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Assemble the adapter pins 6909A, engine support brackets 8130, engine adapters 10107 and powertrain support posts J-48839 to the scissor lift table VAS 6131.

-- Position and install the scissor lift table VAS 6131 under the engine.

-- Install safety straps so that they securely hold the powertrain assembly to the scissor lift table. Tighten the bolts at the base of each powertrain support post J-48839, and verify that the powertrain support posts J-48839 are fully engaged in the lifting points.

Fig 45: Identifying Engine Mount Bracket Bolts And Nuts
GWWUS62857Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right engine mount to engine bolts (1).

Fig 46: Identifying Engine Mount Bolts
GWWUS62859Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left engine mount to engine bolts (1).

-- Raise the vehicle body off of the powertrain assembly.

-- Support the transmission with a suitable lifting device.

-- Install a suitable lifting device to the engine.

-- Remove the remaining transmission bolts, and separate the transmission from engine.

-- Using the lifting device, install the engine to a suitable engine stand.

scientia non olet · About LEMON Manuals