Engine, Removing: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. 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 -2-.

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 REMOVING .

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

-- Remove the battery, refer to BATTERY .

-- Remove the battery tray, refer to BATTERY TRAY .

-- Remove Engine Control Module (ECM), refer to ENGINE CONTROL MODULE -J623- .

-- If equipped remove the vacuum hose -arrow-.

Fig 2: Identifying Vacuum Hose

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

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.

-- 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.

Fig 3: Identifying Release Buttons

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NOTE: Ignore -2 and 3-.

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

Fig 4: Identifying Retainer

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

Fig 5: Free Electrical Wiring Up To Generator Using 80-200

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

Fig 6: 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 7: 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 8: Identifying Connector And Wastegate Bypass Regulator Valve

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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- .

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

-- Free up the wiring harness.

-- Remove the metering line -2-.

Fig 9: Identifying Clamps And Reducing Agent Line

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

-- 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 Set VAS 6122.

Fig 10: Pressing Securing Clip Then Remove Delivery Line

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

Fig 11: Identifying Engine Control Module (E-Box) Cover

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-- Disconnect the connectors -1-.

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

-- Remove the ground connection -3- and free up the wiring harness.

Fig 12: Connectors And Cable Guide

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-- Unclip all wires from the cable guide.

-- Disconnect the connector right -arrow-.

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

-- Disconnect and remove the engine wiring connector from the engine control module, refer to ENGINE CONTROL MODULE -J623- .

Fig 13: Identifying Bracket

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

Fig 14: 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-.

-- Unclip the wiring harness from the coolant reservoir.

-- Remove the bolts -3- and the coolant expansion tank -2-.

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

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

Fig 15: Identifying Coolant Reservoir, Bolts And Connector

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-- 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 16: Identifying Fuel Line Couplers

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Vehicles With A Manual Transmission

-- Remove the selector mechanism from the transmission, refer to SHIFT MECHANISM .

-- Remove the hose/line assembly or plastic hose from the clutch slave cylinder, refer to REMOVING .

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

Fig 17: Identifying Park/Neutral Position Switch

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-- Disengage and disconnect connector -2-.

Fig 18: Identifying Connector

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-- Free up the wiring harness for both connectors.

-- Remove the selector mechanism from the transmission, refer to SHIFT MECHANISM .

Continuation For All Vehicles

-- Remove the front wheels, refer to REMOVAL AND INSTALLATION .

-- Remove the noise insulation, refer to EXTERIOR EQUIPMENT .

-- Remove the right and left front wheel housing liners, refer to REMOVING .

-- Remove the subframe, refer to FRONT SUSPENSION .

-- Remove the right and left driveshaft, refer to FRONT SUSPENSION .

-- Remove the right driveshaft heat shield, refer to FRONT SUSPENSION .

-- 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 VAS 6208 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.

Fig 19: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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

-- Remove the radiator, refer to RADIATOR .

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

Fig 20: Identifying Engine Mount

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Vehicles with Triple Transmission Screw Connection

Fig 21: Identifying Bolts

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

Vehicles with Double Transmission Screw Connection

Fig 22: Identifying Bolts

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

Vehicles With Air Conditioning (A/C)

-- Remove the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

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

CAUTION: There is a risk of damaging the condenser, the A/C compressor and the refrigerant lines and hoses.

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

-- Remove the bolts -arrows-.

Fig 23: Identifying A/C Compressor Components

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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:

-- Disconnect the connector -4-.

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

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

Fig 24: Identifying Charge Air Cooling Pump

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

Fig 25: 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 26: Identifying Engine And Gearbox Jack With Engine Support

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-- Place the Engine/Gearbox Jack VAG 1383A or VAS 6931 on the Engine Support T10497.

-- Slightly lift the engine/transmission subassembly.

-- Remove the bolts -arrows- for the engine mount -1- completely.

Fig 27: Identifying Engine Mount

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Vehicles with Triple Transmission Screw Connection

Fig 28: Identifying Bolts

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

Vehicles with Double Transmission Screw Connection

Fig 29: Identifying Bolts

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

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 electric wires between the engine, the transmission and the body are loosened.
Carefully lower and guide the engine/transmission subassembly out of the engine compartment.

-- Drain the engine/transmission assembly.