Engine, Removing: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Passat. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The engine is removed downward together with the transmission.

During installation, all cable ties must be installed at the same location.

When installing, secure all heat shield boots back in the same positions.

-- Remove the cap -1- in direction of -arrow- from the coolant reservoir.

Fig 1: Identifying Coolant Reservoir

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WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.

-- Remove the engine cover, refer to ENGINE COVER .

-- Remove the air filter, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the battery, refer to[For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- Remove the battery tray, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- Remove Engine Control Module (ECM), refer to Engine Control Module -J623-, REMOVING AND INSTALLING or Engine Control Module -J623- WITH PROTECTIVE HOUSING, REMOVING AND INSTALLING .

CAUTION:

Depending on the vehicle equipment level and market-specific crankcase ventilation hose may be used, which cannot be removed from the cylinder head cover without being destroyed. For these version the crankcase ventilation hose can only be separated at the air guide hose connection.

-- Remove the hose -1- for the crankcase ventilation on the air guide hose.

Fig 2: Identifying Release Buttons

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-- To do this press the release button.

-- Release the connector from the air guide hose and remove.

-- Unclip the wires on the intake tube.

-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Remove bolt -2- and tilt the air guide hose with the intake tube backward and remove from the turbocharger.

-- Open the retainer -arrow- and remove the vacuum hose -1-.

Fig 3: Identifying Retainer

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NOTE:

Use the Pry Lever 80-200 for removing the spiral clips in the following procedure.

Fig 4: Free Electrical Wiring Up To Generator Using 80-200

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-- Free up the wires from the connectors -1 to 3-.

Fig 5: Disconnect The Black

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-- Free up the wiring harness from the cylinder head cover.

-- Disconnect and remove the connector -1- (attached behind the bracket).

Fig 6: Disconnect Connectors

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-- Unclip the connector -1-.

-- Guide the lines out of the brackets -2- on the plenum chamber bulkhead and turbocharger.

-- Unlock and disconnect the connector -2- from the Wastegate Bypass Regulator Valve -N75- -1-.

Fig 7: Identifying Wastegate Bypass Regulator Valve And Nuts

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-- Remove the nuts -arrows-.

-- Set the Wastegate Bypass Regulator Valve -N75- -1- with vacuum lines on the engine.

-- Remove the NOx Sensor -G295- control module and place on the engine with the lines, refer to NOx Sensor -G295-, REMOVING AND INSTALLING .

-- Release the connector from the Reducing Agent Injector -N474- from the plenum chamber bulkhead and remove.

Fig 8: Identifying Metering Line And Wire Connection

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-- Free up the wiring harness.

-- Remove the metering line -2-.

-- To remove the clip push the wire connection -1- together as shown in the direction of the -arrow 1-.

Fig 9: Press The Securing Clip Then Remove The Delivery Line In The -Direction Of Arrow 2

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-- Remove the delivery line in the direction of -arrow 2- without special equipment and without sharply pulling on it.

-- Seal all the open lines and connections with clean plugs from the Engine Bung SetVAS6122.

-- Remove the E-box cover inside the engine compartment -arrows-.

Fig 10: Identifying Engine Control Module (E-Box) Cover

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-- Disconnect the connectors -1-.

Fig 11: Connectors And Cable Guide

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-- Unclip the connector -1- and the locking mechanism -arrows- and open the cable guide -2-.

-- Remove the Ground (GND) connection -3- and free up the wiring harness.

-- Unclip all wires from the cable guide.

-- Disconnect the connector -right arrow-.

Fig 12: Identifying Bracket

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-- Remove the wiring harness from the bracket -1-.

-- Disconnect and remove the engine wiring connector from the Engine Control Module (ECM), refer to Engine Control Module -J623-, REMOVING AND INSTALLING or.Engine Control Module -J623- WITH PROTECTIVE HOUSING, REMOVING AND INSTALLING

-- Loosen the nuts -arrows- and disconnect the battery positive cables -1- from the E-box -2-.

Fig 13: Identifying Battery Cables

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-- Disconnect all other connectors between the starter, transmission and body.

-- Free up the wires.

-- Disconnect and remove the connector for the coolant reservoir -2-.

Fig 14: Identifying Coolant Reservoir, Bolts, And Connector

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-- Unclip the wiring harness from the coolant reservoir.

-- Remove the bolts -3- and the coolant reservoir -2-.

-- Unclip the lines -1- and free up.

-- Lay the coolant reservoir -2- on the engine.

-- Remove the fuel filter and lay with wires connected on the engine, refer to Fuel Supply .

-- Open the couplings -A and B- and remove the fuel lines. Open the couplings, refer to Fuel Supply .

Fig 15: Identifying Fuel Line Couplers

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Vehicles with A Manual Transmission

-- Remove the selector mechanism from the transmission, refer to [For transmission(s) 0A4] Controls, Housing [For transmission(s) 02Q] Controls, Housing [For transmission(s) 02E] Controls, Housing .

-- Remove the hose/line assembly or plastic hose from the clutch slave cylinder, refer to [For transmission(s) 0A4] Clutch [For transmission(s) 02Q] Clutch [For transmission(s) 02E] Clutch .

-- Disconnect the connector from the Park/Neutral Position Switch -E17- -2-.

Fig 16: Identifying Park/Neutral Position Switch

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-- Disengage and disconnect connector -2-.

Fig 17: Identifying Connector

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-- Free up the wiring harness for both connectors.

-- Remove the selector mechanism from the transmission, refer to [For transmission(s) 0A4] Controls, Housing [For transmission(s) 02Q] Controls, Housing [For transmission(s) 02E] Controls, Housing .

Continuation for All Vehicles

-- Remove the front wheels, refer to Wheels, Tires and Vehicle Alignment .

-- Remove the noise insulation, refer to NOISE INSULATION .

-- Remove the right and left front wheel housing liners, refer to WHEEL HOUSING LINER .

-- Remove the subframe, refer to GENERAL INFORMATION GENERAL INFORMATION .

-- Remove the right and left drive axle, refer to GENERAL INFORMATION GENERAL INFORMATION .

-- Remove the right drive axle heat shield, refer to GENERAL INFORMATION GENERAL INFORMATION .

-- Remove the front exhaust pipe, refer to FRONT EXHAUST PIPE .

-- Remove the fan shroud, refer to FAN SHROUD WITH COOLANT FAN .

-- Unclip the wiring harness from the Engine Preheating Element -Z97- on the bumper cover and the bracket, refer to OVERVIEW - ENGINE PRE-WARMER .

-- Lay the lines on the transmission.

-- Place the Shop Crane - Drip Tray VAS6208 underneath.

-- Drain the coolant, refer to COOLANT, DRAINING AND FILLING .

NOTE:

Place a cloth under the heater core for the heater, to catch escaping coolant.

-- Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger.

Fig 18: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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-- Remove the radiator, refer to RADIATOR .

-- Loosen the bolts -arrows- on the engine mount -1- approximately 2 turns.

Fig 19: Identifying Engine Mount

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-- Loosen the bolts -arrows- on the transmission mount approximately 2 turns.

Fig 20: Identifying Bolts

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Vehicles with Air Conditioning

Fig 21: Identifying A/C Compressor Components

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-- Remove the ribbed belt, refer to RIBBED BELT .

-- Disconnect the connector -1- on the A/C Compressor Regulator Valve -N280-.

CAUTION:

There is a risk of damaging the condenser, the Air Conditioning (A/C) compressor and the refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the bolts -arrows-.

WARNING:

Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side.

Continuation for All Vehicles

Fig 22: Identifying Connector, Nut, Bolts, Coolant Pipe And Charge Air Cooling Pump

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-- Disconnect the connector -4-.

-- Remove the nut -2- and the bolts -3-.

-- Push aside the coolant pipe -1- and the Charge Air Cooling Pump -V188- -5-.

-- Loosen the fasteners -arrows- and remove the noise insulation -1-.

Fig 23: Identifying Noise Insulation

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-- Fasten the Engine Support T10497 on the cylinder block with the Pins T10497/1 and the bolt -1- to approximately 20 Nm.

Fig 24: Identifying Engine And Gearbox Jack With Engine Support

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-- Place the Engine and Gearbox Jack VAG1383A or VAS6931 on the Engine Support T10497.

-- Slightly lift the engine/transmission subassembly.

NOTE:

Use a step ladder such as Step Ladder VAS5085 to remove the subframe mount bolts.

Fig 25: Identifying Engine Mount

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-- Remove the engine mount bolts -arrows- completely.

-- Remove the transmission mount bolts -arrows- completely.

Fig 26: Identifying Bolts

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CAUTION:

Danger of causing damage to the vacuum lines or electric wires as well as to the engine compartment.

Make sure all the vacuum lines or wires between the engine, the transmission and the vehicle body are loosened.
Carefully lower and guide the engine/transmission subassembly out of the engine compartment.

-- Drain the engine/transmission assembly.