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 - Engine Bracket:2024A/1 for the Engine Sling:2024A
Engine and Gearbox Jack:VAS6931
Step Ladder:VAS5085
Shop Crane - Drip Tray:VAS6208
Hose Clip Pliers:VAS6362
Engine/Gearbox Jack - Engine Support:T10359
Engine/Gearbox Jack - Pin:T10359/2
Engine/Gearbox Jack - Adapter:T10359/3
Protective eyewear
Safety Gloves

Procedure

Fig 1: Identifying Coolant Reservoir Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

The cooling system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

Wear safety gloves.
Wear protective eyewear.
Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the cap -arrow- from the coolant expansion tank.

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

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

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

-- Remove the battery tray. Refer to BATTERY, REMOVING AND INSTALLING .

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

-- To prevent damage, cover the charge air cooler using suitable workshop equipment.

-- Loosen the hose clamps -1 and 3-.

Fig 2: Identifying Lower Air Guide Pipe

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector from the Charge Air Pressure Sensor -G31- -arrow-.

-- Remove the bolts -2 and 4- and remove the lower air duct pipe -5-.

-- Remove the vacuum hose -3- from the connector -arrow- and remove the vacuum line -2-.

Fig 3: Identifying Vacuum Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the vacuum hose release buttons -2- and remove from the vacuum pump -1-.

-- Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger.

Fig 4: Identifying Heater Core Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

There may be a heat shield installed, which does not need to be removed.

-- Hold the coolant hoses downward and drain the coolant.

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

Vehicles with Secondary Air Injection System

-- Open the release -arrows- and remove the lines -1- from the Secondary Air Injection Pump Motor -V101- -2-.

Fig 5: Locating Release

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for All Vehicles

-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Disconnect the hose couplings -1 and 2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING . Loosen the hose clamp from the expansion tank -3-.

Fig 6: Identifying Expansion Tank

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the nuts -arrows- and disconnect the battery positive cables -1- from the E-box -2-.

Fig 7: Identifying Battery Cables

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Secondary Air Injection System

-- Squeeze the locking ring on both sides and remove the connecting pipe -1-.

Fig 8: Identifying Connecting Pipe And Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully unclip the secondary air system bracket -4-.

Fig 9: Identifying Brackets And Clips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip clip -3- and remove both secondary air lines.

Continuation for All Vehicles

-- Remove the ground connection -2- and free up the cable guide -1-.

-- Release and disconnect the connectors -3-.

Fig 10: Locating Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the locking mechanisms -arrows- for the wiring guide -1-. Place the wiring harness on the engine.

-- Disconnect and remove the connector -arrow-.

Fig 11: Identifying Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the wiring harness from the bracket -1-.

-- Remove the selector lever cable from the transmission.

Fig 12: Identifying Selector Lever Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows- and set the selector lever cable -2- with cable bracket -1- aside.

NOTE:

Do not bend or kink the selector lever cable.

EVAP Canister in the Engine Compartment

Fig 13: Locating Tab

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the vent line -arrow-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Release the tab -3- in direction of -arrow- and remove the EVAP canister -1- upward.

-- Lay the EVAP canister -1- on the engine with the line attached -2-.

Continuation for All Vehicles

Fig 14: Identifying Coolant Expansion Tank And Windshield Washer Fluid Reservoir Filler Tube

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -4- and rotate the windshield washer fluid reservoir filler tube -2- forward.

-- Open the clip -3- and remove the connector -5- from the coolant expansion tank -1-.

-- Remove the bolts -arrows- and place the coolant expansion tank -1- on top of the engine with the hoses connected.

-- Loosen the bolt -1- for the engine mount -2- approximately two turns.

Fig 15: Identifying Engine Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -2- on the transmission mount -1- two turns.

Fig 16: Identifying Transmission Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pivot the tensioner in direction of -arrow- to relieve tension on ribbed belt.

Fig 17: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the tensioning system using the :T10060A .

CAUTION:

Danger of frostbite from refrigerant.

Do not open the A/C system refrigerant circuit.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioning device.

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

Fig 18: Identifying A/C Compressor Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached.

-- Remove the left and right drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Vehicles with Coolant Auxiliary Cooler

Fig 19: Identifying Auxiliary Cooler And Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nuts -arrows- from the coolant auxiliary cooler bracket -2-.

-- Unclip the air guide on the coolant auxiliary cooler.

-- Remove the coolant auxiliary cooler -1- with the bracket -2- and attached coolant hoses and secure to engine.

Continuation for All Vehicles

Fig 20: Identifying After-Run Coolant Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the connector -arrow- from the After-Run Coolant Pump -V51- -1-.

-- Remove the nut -3- and remove the After-Run Coolant Pump -V51- -1- from the bracket -2-.

-- Operate the release -arrow- and remove the coolant hose -1- from the controller housing.

Fig 21: Identifying Coolant Hose Release

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows- and move the bracket to the side.

Fig 22: Identifying Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -arrow- for the bracket -1-.

Fig 23: Identifying Bracket Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lightly push the wires -2- upward.

-- Position the :T10359/3 on the :T10359 from above and secure it.

Fig 24: Identifying Engine/Gearbox Jack Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten :T10359/2 with support element -A- from the :3282 to the engine bracket.

-- Position the :T10359 on the :VAG1383A and bring it into position with the engine/transmission assembly.

-- After the :T10359 is positioned correctly, install the bolt -A- with the spacer sleeve on the :T10359 .

Fig 25: Identifying Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the engine bracket on engine using the securing element -B- from the :3282 and slightly lift the engine/transmission subassembly.

-- Carefully remove the bolts -1- for the engine mount -2-.

Fig 26: Identifying Engine Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -2- completely.

Fig 27: Identifying Transmission Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Depending on the transmission there can be two or three bolts.

-- Carefully lower the engine/transmission subassembly in direction of -arrow 1-.

Fig 28: Identifying Engine Jack

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Carefully guide the engine/transmission subassembly forward and out to the left in direction of -arrow 2-.