Engine, Removing

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

WARNING:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
For example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum lines.
Ensure sufficient clearance to all moving or hot components.

Special tools and workshop equipment required

Lifting Tackle 3033
Hose Clamps - Up To 25mm 3094 (with manual transmission.)
Torque Wrench 1331 5-50Nm VAG1331
Torque Wrench 1332 40-200Nm VAG1332
Step Ladder
Shop Crane VAS 6100
Shop Crane - Drip Tray VAS 6208
Hose Clip Pliers VAS 6362
Transportation Lock T10404
Engine Bung Set VAS 6122
Wrench - Sw13T10384
Engine And Transmission Holder VAS 6095

CAUTION:

Follow the safety precautions when working on the diesel direct injection system. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

NOTE:

Engine and transmission mount overview. Refer to .

Cooling system component overview, body side. Refer to COOLING SYSTEM COMPONENT OVERVIEW, BODY SIDE .

Fuel filter overview. Refer to FUEL FILTER OVERVIEW .

Turbocharger and exhaust manifold with attachments overview. Refer to TURBOCHARGER WITH EXHAUST MANIFOLD AND ATTACHMENTS OVERVIEW .

Charge air cooling system component overview. Refer to CHARGE AIR COOLER COMPONENT OVERVIEW .

Particulate filter with NOx reduction catalytic converter overview. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

Exhaust Gas Recirculation (EGR) system component overview. Refer to EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .

Hose connections are secured with either spring type or clamp type clamps.

Always replace clamp type clamps with spring type clamps.

Hose Clip Pliers VAS 6362 or Hose Clip Pliers VAS 6340 are recommended for installing spring clamps.

To perform this procedure, the battery ground cable must be disconnected. See if a coded radio is installed. If so, obtain the anti-theft code beforehand.

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

The engine is removed forward together with the transmission.

WARNING:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
For example, fuel lines, hydraulic hoses, Evaporative Emission (EVAP) hoses, coolant hoses, refrigerant lines, brake fluid lines and vacuum lines.
Ensure sufficient clearance to all moving or hot components.

Requirements

The ignition is turned off.
The engine must be cold.

Removing

-- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Refer to "Vehicle Self-Diagnosis" in the vehicle diagnostic tester.

-- Remove the engine cover. Refer to ENGINE COVER .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

-- Remove the intake tube between the Mass Airflow Sensor -G70- and intake duct. Loosen the hose clamps using Hose Clip Pliers VAS 6362.

CAUTION:

Electronic components could be destroyed when the battery is disconnected:

Follow the required steps when disconnecting the battery.

-- Turn off the ignition and disconnect the ground cable -arrow- from the battery. Refer to Removal and Installation .

Fig 1: Battery Ground Strap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the battery, the battery tray bolts -arrows- and the tray.

Fig 2: Battery Carrier Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector from the Engine Control Module -J623-. Refer to one of the following:

Jetta from MY 2011, refer to Engine Control Module -J623- .

-- Release the engine wiring harness retainer -A- and remove it upward in the -direction of arrow-.

Fig 3: Identifying Engine Wiring Harness Retainer

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the E-box cover by sliding both latches in the direction of -arrows-.

Fig 4: Identifying E-Box Cover And Latches

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-- Remove the nuts and disconnect the generator wire -A- and the battery wire -B- from the fuse holder.

Fig 5: Identifying Generator Cable -A- And Battery Cable -B-

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

Fig 6: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -arrow- from the starter.

Fig 7: View Of Connector From Starter

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-- Remove the ground wire from the transmission bracket.

-- Disconnect the connector for the Exhaust Gas Temperature Sensor 2 -G448- -1-, the "black" connector for the Exhaust Gas Temperature Sensor 1 -G235- -2-) and the connector for the Heated Oxygen Sensor -G39- -3- at the plenum chamber bulkhead.

Fig 8: Disconnect The Black

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the Exhaust Gas Temperature Sensor 3 -G495- connector -1- (attached behind the bracket).

Fig 9: Disconnect Connectors

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-- Disconnect the connector -2- for the Differential Pressure Sensor -G505- -1-.

Fig 10: Identifying Exhaust Pressure Sensor -1-, Connector -2-, Bolt -4- And Bracket -3-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -4- and bracket -3- with the Differential Pressure Sensor -G505- -1- in the direction of -arrow- and lay them aside (the wires remain connected).

-- Remove the heat shield and disconnect the connector for the Exhaust Pressure Sensor 1 -G450-. Refer to one of the following:

Engine code CBEA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .
Engine code CJAA, refer to PARTICULATE FILTER WITH NOX REDUCTION CATALYTIC CONVERTER OVERVIEW .

-- Disconnect the wire from the Exhaust Pressure Sensor 1 -G450-. Remove the hose clamp using Hose Clip Pliers VAS 6362.

-- Remove the bolts and bracket with the Exhaust Pressure Sensor 1 -G450- and lay them aside (the wire to the particulate filter remains connected).

-- Remove the Wastegate Bypass Regulator Valve -N75- from the retainer and lay it on the engine.

-- Remove the bolt -arrow- and move the windshield washer fluid reservoir filler tube to the side.

Fig 11: Identifying Coolant Expansion Tank Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the coolant expansion tank and lay it on the engine (the coolant hoses remain connected).

-- Remove the fuel filter. Refer to FUEL FILTER .

-- Remove the Auxiliary Fuel Pump -V393-. Refer to Auxiliary Fuel Pump -V393- (IN-LINE ELECTRIC FUEL PUMP) .

-- Disconnect the vacuum hose from the brake booster.

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

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Disconnect all the coolant lines between the engine and radiator. Refer to COOLING SYSTEM COMPONENT OVERVIEW, BODY SIDE .

-- Open the quick-release couplings to the heater core -arrows- at the plenum chamber bulkhead.

Fig 12: Heater Core Hoses Quick-Release Couplings

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Collect any leaking fluid using the Shop Crane - Drip Tray VAS 6208.

-- Disconnect all the connecting hoses between the engine and charge air cooler. Refer to CHARGE AIR COOLER COMPONENT OVERVIEW .

-- Extract the refrigerant from the Air Conditioning (A/C) system. Refer to Description and Operation .

-- Remove the refrigerant lines from the A/C compressor and condenser and secure them to the body without tension.

-- Remove the lock carrier. Refer to Removal and Installation .

-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 13: Identifying Protective Cap For Drive Axle On Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the drive axles from the transmission only. Refer to Removal and Installation .

CAUTION:

The coupling elements between the particulate filter and NOx reduction catalytic converter can be damaged. When removing and installing:

Do not bend the coupling element more than 10°.
Do not stretch the coupling element.
Do not damage the wire mesh on the coupling element.
Use the Transportation Lock T10404 to secure the unlocking element from over bending.

-- Remove the lower bracket for the particulate filter.

-- Remove the Exhaust Gas Recirculation (EGR) filter, refer to -item 9- in the EXHAUST GAS RECIRCULATION SYSTEM COMPONENT OVERVIEW .

NOTE:

Remove the nuts above the bracket using the Wrench - Sw13T10384.

-- Remove the bolt -arrow- on the top bracket for the particulate filter. Loosen the bracket on the cylinder head.

Fig 14: Identifying Cylinder Head Bracket Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamp -1- between the particulate filter and the turbocharger.

Fig 15: Clamp Between Particulate Filter And Turbocharger

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the particulate filter to the body without tension.

With a Manual Transmission

-- Remove the shift mechanism from the transmission. Refer to [For transmission(s) 02Q] Removal and Installation [For transmission(s) 02E] Removal and Installation .

-- Pinch off the hose leading to the master cylinder using a Hose Clamps - Up To 25mm 3094.

Fig 16: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the clip -arrow- out until it stops, for the hydraulic clutch hydraulic line -A-.

Fig 17: Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the hydraulic line -A- from the breather/slave cylinder and seal it off.

CAUTION:

Do not operate the clutch pedal any more.

With a Direct Shift Gearbox (DSG®)

-- Disconnect the selector lever cable from the transmission. Refer to Removal and Installation .

Continuation for All

-- Disconnect all necessary remaining electrical wires from the engine and transmission and set aside.

NOTE:

Verify that all hose and wire connections between the engine, transmission and body have been disconnected.

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

Fig 18: Identifying Pendulum Support & Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Lifting Tackle 3033 as follows and support the engine/transmission subassembly using the Shop Crane VAS 6100.

Fig 19: Identifying Lifting Tackle 3033

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vibration damper side:

Position 2.

Flywheel side:

Position 8.

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

Fig 20: Identifying Engine Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

With a Manual Transmission

Fig 21: Identifying Bolts For Subframe Mount At Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

With a DSG®

Fig 22: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Continuation for All

NOTE:

When removing the engine/transmission subassembly, guide it out carefully to avoid damaging it.

-- Raise the engine/transmission subassembly slightly and remove it toward the front.

-- Separate the transmission from the engine. Refer to TRANSMISSION AND ENGINE, SEPARATING AND ASSEMBLING .

Secure the engine to the Engine And Transmission Holder VAS 6095 when working on it. Refer to ENGINE, SECURING TO Engine And Transmission Holder VAS 6095 .