Engine, Removing

Special Tools And Workshop Equipment Required

Pry Lever 80-200
Engine Sling 2024A
Engine and Gearbox Jack VAS 6931
Hose Clip Pliers VAG 1921
Hose Clip Pliers VAS 6362
Step ladder such as Step Ladder VAS 5085
Engine Bung Set VAS 6122
Shop Crane - Drip Tray VAS 6208
Engine/Gearbox Jack - Engine Support T10359A with Engine/Gearbox Jack - Pin T10359/2
Transmission Support 3282

NOTE:

To perform this procedure, the ground cable must be disconnected from the battery. See if a coded radio is installed. If so, obtain the anti-theft code beforehand.

The engine is removed downward together with the transmission.

All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the 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 the Diagnostic Trouble Code (DTC) memories of all control modules before removing the engine, refer to the vehicle diagnostic tester.

-- Disconnect the battery Ground (GND) cable with the ignition turned off, 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 battery, the battery tray bolts -arrows- and tray.

Fig 1: Battery Carrier Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the plenum chamber cover, refer to the following:

Tiguan, refer to "Moldings and Trim" in DESCRIPTION AND OPERATION .

-- Disconnect the engine wiring harness connector from the Engine Control Module -J623-, refer to the following:

Tiguan

-- Disconnect the engine wiring harness connector from the Engine Control Module -J623-, refer to ENGINE CONTROL MODULE -J623- .

Continuation for All

Fig 2: Identifying Pass-Through For Engine Wiring Harness

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

-- Remove the E-box cover by sliding both latches in the direction of the -arrows-.

Fig 3: Identifying E-Box Cover And Latches

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-- Remove the generator cable nut -A- and the battery cable -B- from the fuse holder.

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

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-- Remove the bolt -arrow- and ground wire from the longitudinal member.

Fig 5: Ground (GND) Cable On Longitudinal Member

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

Fig 6: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

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-- Free up the electrical connector -1- and disconnect in the direction of the -arrow-.

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

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

-- Take the Engine Control Module -J623- wiring harness out of the wiring router and lay it on the engine.

With a Manual Transmission

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

-- Clamp off the hose leading to the master cylinder using the Hose Clamps up to 25mm Diameter 3094.

Fig 8: Identifying Hose Clamps 3094, Clamp Supply Hose And Master Cylinder

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-- Pull out the clip -arrow- for the hose/line assembly.

Fig 9: Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

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

CAUTION:

Do not press the clutch pedal.

For Tiguan, with Automatic Transmission

-- Remove the transmission oil cooler lines from the transmission, refer to REMOVAL AND INSTALLATION .

Continuation for All

-- Disconnect the connector -2-.

Fig 10: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

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-- Remove the fan shroud upper bolts -upper arrows-.

Fig 11: Coolant Fan Control (FC) Control Module J293

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-- Loosen the hose clamp -2-.

Fig 12: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

-- Disconnect the connector -arrow- and free up the electrical 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 the coolant expansion tank cap with a cloth and open carefully.

-- Open the coolant expansion tank cap.

-- Remove the noise insulation, refer to one of the following:

For GTI and Tiguan, refer to DESCRIPTION AND OPERATION

-- Remove the front part of the wheel housing liner or the entire front wheel housing liner, refer to FRONT WHEEL HOUSING LINER .

-- Remove the charge air hoses -arrows-.

Fig 13: Disconnecting Charge Air Hoses

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-- Disconnect the connector -1- and remove the fan shroud lower bolts -lower arrows-.

Fig 14: Coolant Fan Control (FC) Control Module J293

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-- Remove the fan shroud downward.

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

Fig 15: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 16: ECT Electrical Connector

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-- Place the Shop Crane - Drip Tray VAS 6208 under the engine.

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

-- Remove the coolant hoses -1 and 2-.

Fig 17: Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

-- Disconnect the lines at the bracket.

Fig 18: Identifying Breather Line, Vacuum Line & Fuel Supply Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-1- Vent line

-2- Vacuum line

-3- Fuel supply line

Fig 19: Identifying Upper Coolant Hose -Arrow-

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

Tiguan

-- Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.

Continuation for All

Fig 20: Identifying Heater Core Hoses -Arrows-

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-- Remove the bracket slightly in order to remove the heater core hoses -arrows-.

-- From above, remove the front exhaust pipe to turbocharger/exhaust manifold nuts -arrows-.

Fig 21: Front Exhaust Pipe/Turbocharger Nuts

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-- Disconnect the vacuum hoses -arrows-.

Fig 22: Identifying Vacuum Hoses

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With Front Wheel Drive (FWD)

Fig 23: Drive Axle Heat Shield Bolts

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

Continuation for All

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

CAUTION:

There is a risk of destroying the used ribbed belt if it is installed in the reversed running direction of the used ribbed belt from when it was removed.

Before removing the ribbed belt, mark the running direction with chalk or a felt tip pen for reinstallation later.

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

Fig 24: Identifying Wrench And Locking Pin -T10060 A-

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-- Secure the belt tensioner using the Locking Pin T10060A.

-- Remove the ribbed belt.

-- Disconnect the connector -1- from the A/C compressor regulator valve.

Fig 25: 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 disconnect the Air Conditioning (A/C) refrigerant lines or hoses from the compressor.

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

CAUTION:

Risk of damaging refrigerant lines and hoses.

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

-- Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.

-- Remove the generator, refer to REMOVAL AND INSTALLATION .

Continuation for All

Fig 26: After-Run Coolant Pump V51 Bracket Bolt

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-- Remove the after-run coolant pump bracket bolt -2-.

NOTE:

The after-run coolant pump stays in the installed position.

-- First, remove the bolt -1-, then remove bolts -2 and 3- and then remove the pendulum support.

Fig 27: Identifying Support Bracket, Pendulum And Bolts

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

-- Disconnect all coolant, vacuum and intake hose connections from the engine.

CAUTION:

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

Install the Engine/Gearbox Jack - Pin T10359/2 to the Engine/Gearbox Jack - Engine Support T10359 -1- and then install the transmission support.

Fig 28: Identifying Engine Support With Additional Supports
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-- Attach the Engine/Gearbox Jack - Engine Support T10359 -1- to the engine and guide it into the mount.

-- Seat the tensioner -3- in order to prevent the engine from tilting out of the Engine/Gearbox Jack - Engine Support T10359.

-- Secure the Engine/Gearbox Jack - Engine Support T10359 -1- to the cylinder block using the bolt -3- and tighten it to approximately 20 Nm.

Fig 29: Identifying Engine Support And Threaded Hole Location

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Install the Engine and Gearbox Jack VAS 6931 to the Engine/Gearbox Jack - Engine Support T10359.

-- Slightly lift the engine and transmission.

NOTE:

Use a step ladder to remove the engine and transmission mount to bracket bolts.

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

Fig 30: Identifying Engine Mount To Engine Mount Bracket Bolts

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

Fig 31: Identifying Engine Mount To Engine Mount Bracket Bolts

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NOTE:

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

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

With a DSG®

Pay attention to the selector lever cable.

Continuation for All

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

Secure the engine onto the Engine and Transmission Holder VAS 6095 when working on it, refer to ENGINE, SECURING TO THE ENGINE/TRANSMISSION HOLDER .