Engine, Removing

WARNING: This page is about a different car, the 2010 Volkswagen Routan and 2009 Volkswagen Routan. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Scissor Lift Table VAS6131
Powertrain Support Posts J-48839
Support 6912
Support 8444
Adapter Pins 6909A

Fig 1: Identifying Battery Cable And Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Perform the fuel pressure release procedure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .

-- Disconnect the negative battery cable (3).

-- Remove the air cleaner and hoses. Refer to AIR CLEANER HOUSING .

Fig 2: Identifying Fuel Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel line (1) from the fuel rail. Refer to FUEL RAIL .

-- Remove the wiper module. Refer to Removal and Installation .

Fig 3: Identifying Radiator Crossmember

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Block off the heater hoses to the rear heater system using pinch-off pliers, if equipped.

-- Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING .

-- Disconnect the heater hoses.

-- Remove the radiator crossmember (2). Refer to Removal and Installation .

Fig 4: Identifying Throttle Body

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the radiator fans. Refer to COOLING FAN SHROUD .

-- Disconnect the electronic throttle control electrical connector (3) from the throttle body.

-- Disconnect the electrical connectors for the following:

Manifold absolute pressure sensor.
Idle air control valve.
Throttle position sensor.

-- Disconnect the electrical connector for the exhaust gas recirculation transducer, if equipped.

-- Disconnect the vacuum hoses from throttle body.

Fig 5: Identifying Power Steering Reservoir

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the brake booster and speed control vacuum hoses.

-- Disengage the wire harness clip from the right powertrain mount.

-- Remove and reposition the power steering reservoir (2).

-- Remove the ground cable bolt and cable from the rear of the cylinder head.

Fig 6: Identifying Ground Cable Bolt And Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the electrical connectors from the following:

Engine coolant temperature sensor
Ignition coils

-- Disconnect the fuel injector electrical connectors and disengage the clip from support bracket.

-- Disconnect the electrical connectors from the camshaft and crankshaft (2) position sensors.

Fig 7: Identifying Air Conditioning System

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Evacuate the air conditioning system. Refer to General Information .

-- Disconnect the A/C compressor electrical connector.

-- Disconnect the A/C lines (2 and 5) from the compressor. Cover and/or seal all openings of the A/C system.

-- Remove the upper radiator hose.

-- Remove the electrical harness clip at the transaxle dipstick tube.

-- Remove the transaxle dipstick tube. Seal the opening using a suitable plug.

-- Remove the transaxle cooler lines.

-- Disconnect the transaxle shift linkage and electrical connectors.

Fig 8: Identifying Crossmember

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Drain the engine oil.

-- Remove the drive axles. Refer to Removal and Installation .

-- Remove the crossmember (5).

Fig 9: Exhaust Manifold Bolts And Nuts, Exhaust Manifold Gasket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the exhaust pipe (4) from the manifold.

-- Remove the front powertrain mount bracket.

-- Remove the rear powertrain mount bracket.

-- Remove the transaxle case cover.

-- Remove the flex plate to torque converter bolts. Mark the torque converter to flex plate orientation for reassembly.

-- Remove the power steering pressure hose support clip attaching bolt.

-- Disconnect the knock sensor electrical connector.

-- Disconnect the engine block heater electrical connector, if equipped.

-- Remove the accessory belt splash shield.

-- Remove the accessory drive belt. Refer to ACCESSORY DRIVE BELT .

-- Disconnect the lower radiator hose.

-- Remove the A/C compressor from the engine.

-- Remove the generator. Refer to Generator (CGUA Engine) .

-- Remove the water pump pulley bolts and position the pulley between the pump hub and housing.

-- Disconnect the oil pressure switch electrical connector.

-- Disconnect wiring harness support clip from engine oil dipstick tube.

-- Install the engine lift tools on the right side rear of engine block.

-- Lower the vehicle.

-- Remove the power steering pump and set aside.

Fig 10: Identifying Supports And Adapter Pins

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Assemble the support 6912, support 8444, adapter pins 6909A and powertrain support posts J-48839 to the scissor lift table VAS6131.

-- Raise the vehicle enough to allow the scissor lift table VAS6131 to be positioned under the vehicle.

Fig 11: Identifying Cradle Frame

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the powertrain support postJ-48839 mounts to allow movement for positioning the posts into the locating holes on the engine. Slowly lower the vehicle and position powertrain support postJ-48839 mounts until the engine is resting on the posts. Tighten all powertrain support postJ-48839 mounts to the cradle frame. This will keep the mounts from moving when removing or installing the engine and transmission.

Fig 12: Identifying Powertrain Support Posts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lower the vehicle so the weight of only the engine and transmission is on the cradle.

-- Install and secure the safety straps to the scissor lift table VAS6131 and around the engine.

-- Remove the right side powertrain mount to engine attaching bolts.

-- Remove the left powertrain mount through bolt.

-- Raise the vehicle slowly. It is necessary to move the engine/transmission assembly with the scissor lift table VAS6131 to allow for removal around body flanges.

Fig 13: Identifying Engine/Transmission Assembly On The Scissor Lift Table

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.