Engine, Removing

Special tools and workshop equipment required

Lifting Tackle 3033
Engine Support T40074
Torque Wrench (5-50 Nm) VAG1331
Torque Wrench (40-200 Nm) VAG1332
Engine-/Gearbox Jack VAG1383 A
Step Ladder VAS5085
Hose Clip Pliers VAS6340
Spring Type Clip Pliers VAS6499
Engine and Transmission Holder VAS6095
Shop Crane - Load Cap = 700-1200 KG VAS6100
Drip Tray for VAS6100 VAS6208
Engine Bung Set VAS6122
Container for Removed Parts VAG1698 A
Cable Ties
High Temperature Grease G 052 133 A2

The engine with the transmission is removed downward. The lock carrier service position is not necessary.

NOTE:

Check the Diagnostic Trouble Code (DTC) memories on all control modules, refer to the vehicle diagnostic tester.

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

Leave the key inside the ignition lock so that the steering lock does not lock up.

Seal off the disconnected fuel and ventilation lines to prevent dirt from getting into the systems.

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.

Use the Container For Removed Parts VAG1698 to store removed parts so that they do not get damaged.

CAUTION:

Note the following whenever working inside the engine compartment due to limited space:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

Turn off the ignition and disconnect the battery ground cable, refer to Removal and Installation .

-- Remove the air filter housing with the connecting pipe, refer to OVERVIEW - AIR FILTER HOUSING .

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

-- Remove the windshield wiper arms and the plenum chamber cover, refer to the following:

Windshield wiper arms, refer to Removal and Installation .

Plenum chamber cover, refer to "Moldings and Trim" in Removal and Installation .

With a Engine Control Module (ECM) Equipped with Anti-Theft Protection

-- Remove the anti-theft protection from the ECM, refer to Engine Control Module -J623- WITH PROTECTIVE HOUSING, REMOVING AND INSTALLING .

Continuation for All

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

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

Fig 1: Identifying Pass-Through For Engine Wiring Harness

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-- Remove the nut -arrow- and the generator cable from the fuse block.

Fig 2: Generator Wire At Fuse Holder

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

Fig 3: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

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-- Disconnect the connector -4-, open the locking mechanism and lay the engine harness -3- on the engine.

Fig 4: Identifying Harness Connector, Engine Wiring Harness, Ground (GND) Wire, Starter Connections & Multi-Function Switch Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the ground cable -1- and the starter connections -2 and 5-.

-- Disconnect the oxygen sensor connector on the plenum chamber bulkhead.

-- Disconnect all connectors from the transmission.

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

-- Disconnect the selector lever cable from the transmission.

WARNING:

The fuel lines are under pressure.

Danger of personal injury to eyes and skin.

Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before removing a fuel hose. Open the connection carefully and release the pressure.

-- Disconnect the fuel supply line -1- and the vent line -2-, refer to "Coupling, Disconnecting" in Description and Operation .

Fig 5: Identifying Supply Line (Metal Coupling)

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-- Disconnect the vacuum line from the brake booster and intake manifold.

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

-- Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

WARNING:

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the cap on the expansion tank and then close it again after releasing the pressure in the coolant system.

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

-- Remove the wheel housing liners, refer to Removal and Installation .

-- Disconnect the connector from the oil level thermal sensor.

-- Remove the oil level thermal sensor wire holder from the subframe and lay it on the subframe.

-- Remove the wires and bracket -arrows- from the front transmission cover.

Fig 6: Identifying Nuts And Bracket

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-- Move the wire near the transmission cover upward and secure them.

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

-- Disconnect the coolant hoses -arrows- from the heater core.

Fig 7: Identifying Heater Core Hoses -Arrows-

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-- Release the clip -arrow-.

Fig 8: Identifying Upper Coolant Hose -Arrow-

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-- Remove the upper radiator coolant hose -1-.

-- Remove the bolt -2- and lay the windshield washer fluid reservoir filler tube -1- forward.

Fig 9: Identifying Bolt, Windshield Washer Reservoir & Connectors

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-- Disconnect the connector -3-.

-- Remove the coolant expansion tank bolts -5- and place the tank -4- on top of the engine with the hoses connected.

NOTE:

Loosen the bolts on the engine and transmission mounts one turn.

WARNING:

Refrigerant can cause serious personal injury.

Do not open the Air Conditioning (A/C) refrigerant circuit.

So that it is possible to remove the engine without opening the refrigerant circuit:

-- Remove the A/C compressor from the accessory bracket, refer to Removal and Installation .

CAUTION:

Risk of damaging refrigerant lines and hoses.

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

-- Secure the A/C compressor to the bumper cover using a Tensioning StrapT10038 and a suitable mat -A-. Slide the Tensioning StrapT10038 as far as possible onto the bolt -arrow-.

Fig 10: Identifying A/C Compressor Secured On Bumper Cover Using Tensioning Strap T10038 And Matching Base

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-- Remove the right drive axle heat shield nuts -1- and shield.

Fig 11: Drive Axle Heat Shield -- All Wheel Drive

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-- Remove the both drive axles, refer to Removal and Installation .

-- Remove the driveshaft flexible disc bolts from the bevel bolt output flange, refer to Removal and Installation .

CAUTION:

Danger of causing damage to the coupling element:

Do not bend the coupling element more than 20°.
Do not stretch the coupling element.
Do not damage the wire mesh on the coupling element.

-- Remove the exhaust pipe with catalytic converter to exhaust manifold nuts -arrows-.

Fig 12: Front Exhaust Pipe Nuts And Exhaust Manifolds

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-- Remove the rear clamping sleeve and suspended mount from the exhaust pipe. Remove the exhaust pipe with catalytic converter and oxygen sensors.

NOTE:

The oxygen sensors can remain installed.

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

Fig 13: Identifying Support Bracket, Pendulum And Bolts

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-- Install the Engine Support T40074 to the Engine-/Gearbox Jack VAG1383A.

-- Remove the AdapterT40074/1 from the Engine Support T40074 and install it to the cylinder block with a nut -1-.

Fig 14: Identifying Installation Of Adapter T40074/1 To Cylinder Block

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-- Position the Engine Support T40074 to the engine as illustrated and install the AdapterT40074/1 to the Engine Support T40074 with the bolt -2-.

Fig 15: Attaching Adapter T40074/1 To Cylinder Block With Nut And Securing To Engine Support T40074 With Bolt

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-- Tighten the Engine Support T40074 to the exhaust side of the cylinder block with 2 M10 x 25 bolts -arrows- as illustrated and tighten them to 20 Nm.

Fig 16: Identifying Bolts Of Engine Support T40074

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-- Gently lift the engine and transmission using the Engine-/Gearbox Jack VAG1383 A.

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

Fig 17: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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

Fig 18: Identifying Transmission Mount To Transmission Mount Bracket Bolts

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NOTE:

Use Step LadderVAS5085 to remove the bolts.

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

-- Carefully lower the engine with transmission.