Engine, Removing

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

Special tools and workshop equipment required

Pry Lever 80-200
Engine Sling 2024A
Engine and Gearbox Jack VAS6931
Hose Clip Pliers VAG1921 or Hose Clip Pliers VAS6362
Commercially available Step Ladder
Engine Bung Set VAS6122
Shop Crane - Drip Tray VAS6208
Engine/Gearbox Jack - Engine Support T10359A with Engine/Gearbox Jack - Pin T10359/2
Transmission Support 3282

NOTE:

To perform work sequence, the Ground (GND) cable must be disconnected from battery. See if a coded radio is installed. If so, obtain anti-theft coding beforehand.

The engine is removed downward together with the transmission.

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

CAUTION:

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.
Ensure sufficient clearance to all moving or hot components.

-- Check Diagnostic Trouble Code (DTC) memories of all control modules before removing engine, refer to Vehicle Diagnostic Tester.

-- Turn off the ignition and disconnect the battery GND cable, refer to REMOVAL AND INSTALLATION .

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

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

-- Remove the bolts -arrows- and remove the battery tray -1-.

Fig 1: Battery Tray And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the windshield wiper arms, refer to REMOVAL AND INSTALLATION .

-- Remove the plenum chamber cover, refer to REMOVAL AND INSTALLATION .

-- Disconnect the engine wiring harness connector from the Engine Control Module (ECM), refer to ENGINE CONTROL MODULE or ENGINE CONTROL MODULE WITH PROTECTIVE HOUSING .

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

Fig 2: Identifying Pass-Through For Engine Wiring Harness

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the E-box cover in the engine compartment by sliding both latches in direction of -arrow-.

Fig 3: Identifying E-Box Cover And Latches

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the cable from the generator -A- and the cable from the battery -B- on the fuse holder.

Fig 4: Identifying Generator Cable -A- And Battery Cable -B-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the GND wire on the longitudinal member -arrow-.

Fig 5: Ground (GND) Cable On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 6: Identifying Open Wiring Router Bracket And Locating Cable Ties

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up the connector -1- and disconnect.

Fig 7: Identifying Electrical Connector -1- And Wiring Guide Bracket -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the underlying wiring guide bracket -2-.

-- Remove the ECM wiring harness out of the wiring guide and lay it on the engine.

Manual Transmission with Clutch Slave Cylinder

Fig 8: Clutch Slave Cylinder And Brace

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the gearshift mechanism from the transmission, refer to REMOVAL AND INSTALLATION .

-- Remove the brace -1-.

-- Remove the clutch slave cylinder -arrows- and move it to the side. Do not open the line system.

CAUTION:

Do not press the clutch pedal after removing the slave cylinder. Slave cylinder may be damaged by doing this.

Manual Transmission without Clutch Slave Cylinder

Fig 9: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the gearshift mechanism from the transmission, refer to REMOVAL AND INSTALLATION .

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

-- Pull the clamp -arrow- for the line up to the stop.

Fig 10: Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the line out of the ventilator/slave cylinder and seal it off.

Vehicles with DSG®:

-- Remove the selector lever cable from the transmission, refer to SELECTOR MECHANISM or SELECTOR LEVER CABLE, CHECKING AND ADJUSTING [For transmission(s) 02E] Selector Mechanism Overview .

Continuation for All Vehicles

Fig 11: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2-.

-- Remove the upper mounting bolts for the air shroud -arrows-.

Fig 12: Coolant Fan Control (FC) Control Module J293

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the hose clamp -2-.

Fig 13: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -4-.

-- Disconnect the connectors -arrow- and free up the electric wire.

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 coolant reservoir cap with a cloth and carefully opening.

-- Open the coolant reservoir cap.

-- Remove noise insulation, refer to DESCRIPTION AND OPERATION .

-- Remove the front section of the wheel housing liners, refer to REMOVAL AND INSTALLATION .

-- Remove the charge air hoses -arrows-.

Fig 14: Disconnecting Charge Air Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -1- and remove the lower mounting screws -arrows- for the air shroud.

Fig 15: Coolant Fan Control (FC) Control Module J293

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the air shroud downward.

-- Remove the bolt -1- and remove the air guide pipe downward.

Fig 16: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2- for the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.

Fig 17: ECT Electrical Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the Shop Crane - Drip Tray VAS6208 under engine.

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

-- Remove coolant hoses -1 and 2-.

Fig 18: Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

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 loosening hose connections. Open the connection carefully and release the pressure.

-- Disconnect the fuel supply line -1- and the bleeder line -2-, refer to DESCRIPTION AND OPERATION .

Fig 19: Identifying Supply Line (Metal Coupling)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the upper coolant hose from the radiator -arrow-.

Fig 20: Identifying Upper Coolant Hose -Arrow-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- If equipped, remove the heat shield -3- from the bulkhead.

Fig 21: Identifying Nuts, Bolts, Clips And Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the coolant hoses from the heat exchanger -arrows-.

Fig 22: Identifying Heater Core Hoses -Arrows-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From above, remove the nuts -arrows- on the front exhaust pipe connection to the turbocharger.

Fig 23: Front Exhaust Pipe/Turbocharger Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the vacuum hoses -arrows-.

Fig 24: Identifying Vacuum Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the pendulum support from the subframe first -1- and then remove -2 and 3-.

Fig 25: Identifying Support Bracket, Pendulum And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 26: Drive Axle Heat Shield Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the both drive axles, refer to REMOVAL AND INSTALLATION .

-- Remove the front exhaust pipe with the catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

CAUTION:

Risk of damage due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- To release the tension on the ribbed belt, turn the tensioner in direction of -arrow- from underneath.

Fig 27: Identifying Wrench And Locking Pin -T10060 A-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the tensioning system using the Locking Pin T10060A.

-- Remove the ribbed belt.

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

Fig 28: A/C Compressor Bolts And Solenoid Clutch Electrical Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Refrigerant can cause serious personal injury.

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

-- Remove the bolts -arrows- on the A/C compressor.

CAUTION:

Danger of causing damage to the refrigerant lines and hoses.

Do not bend, twist or stretch the refrigerant lines and hoses.

-- Tie up the A/C compressor to the longitudinal member with the refrigerant hoses still connected.

-- Remove the bolt -2- on the bracket for the After-Run Coolant Pump -V51-.

Fig 29: After-Run Coolant Pump V51 Bracket Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The After-Run Coolant Pump -V51- stays in the installed position.

-- If equipped, disconnect the connector -1- on the Oil Level Thermal Sensor -G266- and unclip the bracket -2- on the subframe.

Fig 30: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Disconnect all connection-, coolant-, vacuum- and intake hoses from the engine.

CAUTION:

Always use the Engine/Gearbox Jack - Pin T10359/2 and the Transmission Support 3282. Otherwise the engine will tip over.

Install the Engine/Gearbox Jack - Pin T10359/2 in the Engine/Gearbox Jack - Engine Support T10359A and then install the Transmission Support.

Fig 31: Identifying Engine Support With Additional Supports
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Position the Engine/Gearbox Jack - Engine Support T10359A -1- on the engine and guide it into the mounts.

-- Close the Transmission Support -3- to prevent the engine from tipping out of the Engine/Gearbox Jack - Engine Support T10359A.

-- Using the bolt -3-, fasten the Engine/Gearbox Jack - Engine Support T10359 -1- to approximately 20 Nm on the cylinder block.

Fig 32: Identifying Engine Support And Threaded Hole Location

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The threaded hole for the bolt -3- serves to secure the After-Run Coolant Pump -V51-.

-- Install the Engine and Gearbox Jack VAS6931 on the Engine/Gearbox Jack - Engine Support T10359A.

-- Slightly lift the engine and the transmission.

NOTE:

Use a Step Ladder to remove the subframe mount bolts.

-- Remove the subframe mount bolts -arrows- on the engine.

Fig 33: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the subframe mount bolts -arrows- on the transmission.

Fig 34: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

To prevent damage, carefully guide the engine and transmission when lowering.

Vehicles with DSG®

Pay attention to the selector lever cable.

All:

-- Pull the engine and transmission as far as possible to the left and slowly lower it.

Secure the engine on the Engine and Transmission Holder VAS6095 when performing repair work, refer to ENGINE, SECURING ON ENGINE AND TRANSMISSION HOLDER .