Engine, Removing

WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Engine and Gearbox Jack:VAS6931
Engine Bung Set:VAS6122
Shop Crane - Drip Tray:VAS6208
Hose Clip Pliers:VAS6362
Locking Pin:T10060A
Engine Support:T10497 with Engine Support - Pins:T10497/1
Engine Support - Clamp:T10497/4
Pry Lever:80-200
Protective Mat:VAS531003
Commercially Available Step Ladder
Protective Eyewear
Safety Gloves

CAUTION:

This procedure contains mandatory replaceable parts. Refer to component overview prior to starting procedure.

Mandatory Replacement Parts

Bolts - Engine Mount
Bolts - Transmission Mount

CAUTION:

After the high pressure line assembly, and when installing a new short engine, it is particularly important to tighten the fuel injector tensioning clamps to the previously mentioned tightening specification. Refer to OVERVIEW - FUEL INJECTORS . Only tighten the tensioning claws >>hand tight<< after delivery when assembling the high pressure lines in order to align the fuel injectors. Engine damage may occur if not observed.

Procedure

NOTE:

The engine is removed downward together with the transmission.

During installation, all cable ties must be installed at the same location.

When installing, secure all heat shield boots back in the same positions.

WARNING:

Risk of scalding due to hot steam and hot coolant.

The cooling system is under pressure when the engine is warm.
Cover the coolant expansion tank cap with a cloth and carefully open it to reduce the pressure.

-- Open the coolant reservoir cap -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the subframe. Refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the left and right front sections of the front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Place the :VAS6208 underneath.

-- Drain the coolant. Refer to DRAIN THE COOLANT .

-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Remove the radiator. Refer to RADIATOR, REMOVING AND INSTALLING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the bolt -arrow- on the left and right.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip and remove the lower section -1- of the air duct.

-- Remove the battery tray -1-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the connection on the turbocharger. Refer to TURBOCHARGER CONNECTIONS, REMOVING AND INSTALLING .

-- Remove the NOx Sensor Control Module -J583- and place it on the engine. Refer to NOX SENSOR CONTROL MODULE -GX30-, REMOVING AND INSTALLING .

-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the vacuum hose -1- at the T-connection.

-- Release the retainer in direction of -arrow- and remove the vacuum hose -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Place a cloth under the heater core for the heater to soak up any leaking coolant.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the clips -arrows- and remove the coolant hoses from the heater core for the heater.

-- Disconnect the connectors and free up the wires.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

2 -

For the Exhaust Gas Temperature Sensor 4 -G648-

3 -

For the Exhaust Gas Temperature Sensor 3 -G495-

4 -

For the Oxygen Sensor 1 before Catalytic Converter -GX10-

-- Disconnect the connector -5- on the Fuel Temperature Sensor - G81-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Very hot fuel can cause burns.

In extreme cases, the temperature of the fuel lines and fuel can reach up to 100 °C (212 °F) after stopping the engine. Let the fuel cool down before opening any line connections, otherwise there is a danger of scalding.
Wear safety gloves.
Wear protective eyewear.

-- Loosen the hose clamps -4 and 6- and remove the fuel supply hose and return hose.

-- Loosen the hose clamps -1 and 3- and remove the coolant hoses.

-- Remove the bolt -2-.

-- Unclip the connector -4- from the bracket.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up the wire.

-- Loosen the hose clamp -1-.

-- Remove the coolant hoses -3-.

-- Free up the SCR line -2-.

-- Remove the Reducing Agent Injector -N474- and lay it to the right side.

-- Lift the clamp -arrow- and remove the upper right coolant hose from the charge air cooling circuit cooler.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the clamp -arrow- and remove the left upper coolant hose from the radiator.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Use the :80-200 for the following procedures to unclip the spiral clips.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2- on the Engine Control Module - J623-. Refer to ENGINE CONTROL MODULE -J623-, REMOVING AND INSTALLING .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connectors -1, 3 and 4- from the bracket and disconnect them.

-- Free up the wires.

-- Remove the nut -arrow-, disconnect and free up the wires.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Manual Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2-.

-- Push the B+ terminal protector -1- back and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -3- and remove the ground wire.

-- Disconnect the left front connectors from the transmission:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Transmission Neutral Position Sensor -G701-
Back-Up Lamp Switch - F4-

-- Remove the line on the clutch slave cylinder. Refer to CLUTCH MECHANISM LINES, REMOVING AND INSTALLING .

Vehicles With Dual-Clutch Transmission:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the connector twist lock -1- by turning it in the direction of the starter and then remove the connector.

7-Gear DSG ^® Transmission:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743- by pulling the locking mechanism upward in direction of -arrow-.

-- Disconnect the connector -4-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the cap -5-.

-- Remove the nut -6- and remove terminal 30/B+

-- Remove the ground cable from the body.

Continuation For All Vehicles:

-- Remove the selector mechanism from the transmission. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING .

-- Loosen the bolts -arrows- on the engine mount approximately two turns.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles With Three Transmission Bolted Connections:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the bolts -arrows- on the transmission mount approximately two turns.

Vehicles With Two Transmission Bolted Connections:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the bolts -arrows- on the transmission mount approximately two turns.

-- Remove the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

There is a risk of damaging the A/C compressor, the refrigerant lines and hoses.

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

-- Remove the bolts -arrows-.

WARNING:

Refrigerant can cause serious injury.

Do not open the A/C system refrigerant circuit.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side.

-- Remove the left and right drive axles -arrow- from the transmission (refer to DRIVE AXLE, REMOVING AND INSTALLING ) and tie them up toward the rear.

-- Disconnect the connector -1- on the Exhaust Door Control Unit - J883-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamping sleeve -2- and slide it toward the rear.

-- Loosen the bolt -2- and the screw-type clamp.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front exhaust pipe.

-- Disconnect the connector -4-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut -2- and the bolts -3-.

-- Push the coolant pipe -1- and Charge Air Cooling Pump -V188- -5- to the side.

-- Loosen the fasteners -arrows-, and remove the oil pan noise insulation -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Fasten the :T10497 on the cylinder block with the :T10497/1 and the bolt -1- to approximately 20 Nm.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the :VAS6931 on the :T10497 .

-- Slightly lift the engine/transmission assembly.

NOTE:

Use the Step Ladder to remove the engine mount bolts.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Completely remove the engine mount bolts -arrows-.

-- Completely remove the transmission mount bolts -arrows- completely.

Vehicles With Three Transmission Bolted Connections

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles With Two Transmission Bolted Connections

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Risk of damaging the vacuum lines or wires as well as the engine compartment.

Make sure all the vacuum lines or wires between the engine, the transmission and the vehicle body are loosened.
Carefully lower and guide the engine/transmission assembly out of the engine compartment.

-- Drain the engine/transmission assembly.