Engine, Removing: Procedure

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

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-.

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

-- Remove the subframe. Refer to SUBFRAME .

-- Remove the left and right front sections of the front wheel housing liner. Refer to WHEEL HOUSING LINER .

-- Remove the noise insulation. Refer to 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.

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

-- Remove the battery tray -1-. Refer to BATTERY .

-- 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.

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

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

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NOTE:

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

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

-- Disconnect the connectors and free up the wires.

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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-.

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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.

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-- 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.

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

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NOTE:

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

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

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-- 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.

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Vehicles with Manual Transmission

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-- 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:

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

-- Remove the line on the clutch slave cylinder. Refer to CLUTCH MECHANISM [For transmission(s) 02Q] .

Vehicles with Dual-Clutch Transmission:

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

7-Gear DSG ^® Transmission:

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

-- Disconnect the connector -4-.

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-- 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 CLUTCH MECHANISM [For transmission(s) 02Q] .

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

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Vehicles with Three Transmission Bolted Connections:

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

Vehicles with Two Transmission Bolted Connections:

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-- 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-.

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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 ) and tie them up toward the rear.

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

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

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

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-- Remove the front exhaust pipe.

-- Disconnect the connector -4-.

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-- 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-.

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

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-- Install the :VAS6931 on the :T10497 .

-- Slightly lift the engine/transmission assembly.

NOTE:

Use the Step Ladder to remove the engine mount bolts.

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

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