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Home >> Volkswagen >> 2012 >> Routan S >> Repair and Diagnosis >> External Pages >> Different car >> Section 1632 (4.0L - Engine Assembly - Engine Code: CGVA) >> 10 Engine Assembly >> Removal And Installation >> Engine, Removing
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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 

NOTE: Capture and store any residual fluid drainage, or leakage from ancillary components, in the appropriately marked containers.
Fig 1: Engine Cover
GWWUS62781Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine cover (1).

-- Release the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .

Fig 2: Identifying Positive And Negative Battery Cables
GWWUS62783Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the positive (1) and negative (3) battery cables. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 3: Identifying Wiring Harness Retainer And Battery Tray
GWWUS62785Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness retainer (2), from the battery tray.

-- Remove the battery tray bolts, and remove the battery tray (1).

Fig 4: Identifying Coolant Overflow Hose And Coolant Recovery Reservoir
GWWUS62787Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the coolant overflow hose (1) at the radiator fill cap, and remove the coolant recovery reservoir (2).

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

Fig 5: Identifying Air Filter Housing
GWWUS62789Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the air filter housing (6). Refer to AIR CLEANER HOUSING .

Fig 6: Identifying Wiring Harness Electrical Connectors
GWWUS62791Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connectors (1 and 2) from the cooling fans.

Fig 7: Identifying Left And Right Cooling Fan Clips
GWWUS62793Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the left (1) and right (2) cooling fan clips, and remove the cooling fan assembly.

Fig 8: Drive Belt Tensioner Lug & Accessory Drive Belt
GWWUS62795Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the accessory drive belt (1). Refer to ACCESSORY DRIVE BELT .

Fig 9: Identifying Generator
GWWUS62797Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the generator (1). Refer to Removing .

Fig 10: Identifying Power Steering Line Bracket Bolts
GWWUS62799Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the power steering line bracket bolts (1 and 2).

Fig 11: Identifying Evaporative Emission Purge Solenoid Wiring Harness Electrical Connector And Air Conditioning Pressure Transducer Wiring Harness Electrical Connector
GWWUS62801Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

Fig 12: Identifying Wiring Harness Electrical Connector
GWWUS62803Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (1) from the power steering pump.

Fig 13: Identifying Power Steering Pump And Bolts
GWWUS62805Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the power steering pump bolts (3) and reposition the power steering pump (2).

Fig 14: Identifying Wiring Harness Electrical Connector
GWWUS62803Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator lower hose (2) clamp at the engine.

-- Remove the radiator lower hose (2) from the engine.

Fig 15: Identifying Fuel Supply Line Quick Connect Fitting And Fuel Rail
GWWUS62809Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the fuel supply line quick connect fitting (1) from the fuel rail (2). Refer to QUICK CONNECT FITTING DISCONNECTING AND CONNECTING .

Fig 16: Identifying EVAP Purge Line And Brake Booster Vacuum Hose
GWWUS1033802Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the EVAP purge line (1) and brake booster vacuum hose (2) from the upper intake manifold.

Fig 17: Identifying Radiator Upper Hose
GWWUS1033889Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator upper hose (1) clamp at the engine.

-- Remove the radiator upper hose (1) from the engine.

Fig 18: Identifying Wiring Harness Electrical Connectors
GWWUS62815Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

Fig 19: Identifying Wiring Harness Electrical Connector And Ground Strap Bolt
GWWUS62817Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (1) from the transmission.

Fig 20: Identifying Wiring Harness Retainer
GWWUS62839Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the wiring harness retainer (1) from the transmission shift bracket.

Fig 21: Identifying Transfer Shaft Speed Sensor Wiring Harness Electrical Connector And Output Speed Sensor Wiring Harness Electrical Connector
GWWUS62819Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the following wiring harness electrical connectors:

-- Disconnect the wiring harness electrical connectors from the bank 2 sensor 1 and bank 2 sensor 2 O2 sensors.

Fig 22: Identifying Rear Engine Mount Bracket Bolts
GWWUS62835Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the rear engine mount bracket bolts (1).

Fig 23: Identifying Heater And Power Steering Hose Bracket Bolts
GWWUS62841Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the heater and power steering hose bracket bolts (2) from the left engine mount and transmission bellhousing.

Fig 24: Identifying Front Heater Line Bracket Retainer Bolt
GWWUS62843Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front heater line bracket retainer bolt (1).

Fig 25: Identifying Heater Hoses
GWWUS1034275Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the heater hoses (1) and (2). Refer to QUICK CONNECT FITTING DISCONNECTING AND CONNECTING .

Fig 26: Identifying Oil Cooler Lines
GWWUS62845Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the oil cooler lines (1) from the transmission using disconnect tool 8875A.

Fig 27: Identifying Shift Cable And Transaxle Manual Valve Lever
GWWUS62847Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the shift cable from the bracket.

-- Disconnect the shift cable (1) from the transaxle manual valve lever (2).

Fig 28: Identifying Wiring Harness Electrical Connector And Ground Strap Bolt
GWWUS62817Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front wheels and tires. Refer to Removal and Installation .

-- Remove the oil filter/oil cooler splash shield and the left front wheelhouse liner. Refer to Removal and Installation .

-- Remove the ground strap bolt (2) and reposition the ground strap.

Fig 29: Identifying Wiring Harness Electrical Connector And Inline Harness
GWWUS1034435Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector (2) and the inline harness (2) connector from the powertrain control module.

Fig 30: Identifying Radiator Lower Hose
GWWUS1034470Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Reposition the radiator lower hose (1) clamp at the radiator.

-- Remove the radiator lower hose (1) from the radiator.

Fig 31: Identifying Wire Harness Electrical Connector
GWWUS1034480Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wire harness electrical connector (1) from the oil pressure sensor.

Fig 32: Identifying Engine Oil Cooler Line And Engine Oil Cooler
GWWUS62823Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the engine oil cooler line (7) from the engine oil cooler (3).

Fig 33: Identifying Bolt And Nuts
GWWUS62807Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the wiring harness electrical connector from the air conditioning compressor clutch coil.

-- Remove the bolt (2) and two nuts (3) from the A/C compressor and reposition the A/C compressor.

Fig 34: Identifying Oil Dipstick Tube Bolt
GWWUS62851Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the oil dipstick tube bolt (1), and remove the oil dipstick tube.

-- Remove the left (front) exhaust manifold. Refer to LEFT EXHAUST MANIFOLD .

Fig 35: Battery Cable Nut, Battery Cable, Starter Solenoid Stud & Electrical Connector
GWWUS59549Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the battery cable nut (3) and battery cable (2) from the starter solenoid stud (1).

-- Disconnect the wiring harness electrical connector (4) from the starter solenoid.

Fig 36: Identifying Front Engine Mount Through Bolt
GWWUS62831Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front engine mount through bolt (1).

Fig 37: Identifying Crossmember And Bolts
GWWUS62837Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the crossmember bolts (1 and 2).

-- Remove the crossmember (3).

Fig 38: Identifying Crossunder Pipe Bracket Bolts And Bracket
GWWUS62825Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the crossunder pipe. Refer to EXHAUST CROSSUNDER PIPE .

-- Remove the crossunder pipe bracket bolts (2) and bracket (4) from the bottom of the transmission (1).

Fig 39: Identifying Torque Converter Access Cover Bolt And Cover
GWWUS62827Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the torque converter access cover bolt (3) and cover (2).

Fig 40: Identifying Flexplate Bolt And Transmission Lower Bolts
GWWUS62829Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
NOTE: Upon removing the flexplate bolts (1), some flexplates will have a tight tolerance (slotted) bolt hole. If present, mark this location (on the bolt, flexplate and the converter) with a paint mark for realignment during installation.

-- Remove the torque converter to flexplate bolts (1).

-- Remove the transmission lower bolts (2).

Fig 41: Identifying Front Engine Mount Bracket
GWWUS1035242Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the three front engine mount bracket bolts (1) and the bracket (2).

-- Remove the muffler. Refer to MUFFLER/RESONATOR ASSEMBLY .

-- Remove the right (rear) exhaust manifold. Refer to RIGHT EXHAUST MANIFOLD .

Fig 42: Identifying Engine Mount Heat Shield With Bolts
GWWUS62833Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine mount heat shield bolts (1) and heat shield (2).

-- Remove the rear engine mount through bolt (3).

Fig 43: Identifying Left And Right Drive Axles
GWWUS57653Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left and right drive axles (1). Refer to Removal and Installation .

Fig 44: Identifying Adapter Pins 6909A, Engine Support Brackets 8130, Engine Adapters 10107, Powertrain Support Posts J-48839 And Scissor Lift Table VAS 6131
GWWUS62853Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Assemble the adapter pins 6909A, engine support brackets 8130, engine adapters 10107 and powertrain support posts J-48839 to the scissor lift table VAS 6131.

-- Position and install the scissor lift table VAS 6131 under the engine.

-- Install safety straps so that they securely hold the powertrain assembly to the scissor lift table. Tighten the bolts at the base of each powertrain support post J-48839, and verify that the powertrain support posts J-48839 are fully engaged in the lifting points.

Fig 45: Identifying Engine Mount Bracket Bolts And Nuts
GWWUS62857Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right engine mount to engine bolts (1).

Fig 46: Identifying Engine Mount Bolts
GWWUS62859Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the left engine mount to engine bolts (1).

-- Raise the vehicle body off of the powertrain assembly.

-- Support the transmission with a suitable lifting device.

-- Install a suitable lifting device to the engine.

-- Remove the remaining transmission bolts, and separate the transmission from engine.

-- Using the lifting device, install the engine to a suitable engine stand.

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