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:T10359A
Engine/Gearbox Jack - Pin:T10359/2
Engine/Gearbox Jack - Adapter:T10359/3
Protective Eyewear
Safety Gloves

Procedure

-- Remove the engine cover. Refer to ENGINE COVER .

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 coolant expansion tank cap -arrow-.

Fig 2: Identifying Coolant Reservoir Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 TRAY, REMOVING AND INSTALLING .

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

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

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

Fig 3: 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 air duct pipe -5- downward.

-- Remove the vacuum hose -3- from the connection -arrow- for the vacuum line -2-.

Fig 4: Identifying Vacuum Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Fig 5: Identifying Heater Core Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

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

-- Remove the left and right front wheel housing liners. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

Vehicles with Secondary Air System

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

Fig 6: 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 7: Identifying Expansion Tank

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.

-- Release and disconnect the engine wiring harness connector from the engine control module. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

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

Fig 8: Identifying Battery Cables

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Secondary Air System

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

Fig 9: Identifying Connecting Pipe And Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 10: Identifying Brackets And Clips

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Unclip the 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 11: Locating Connectors

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Disconnect and remove the connectors -arrow-.

Fig 12: 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. Refer to OVERVIEW - SELECTOR MECHANISM

Fig 13: Identifying Selector Lever Cable

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

NOTE:

Do not bend or kink the selector lever cable.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 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.

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

Fig 16: Identifying Transmission Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Lock the tensioner using the :T10060A .

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

Fig 18: Identifying A/C Compressor Components

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Danger of frostbite from refrigerant.

- Do not open the A/C system refrigerant circuit.

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

-- 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 duct 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.

-- Disconnect the connector -arrow- from the Heater Support Pump -V488- -1-.

-- Remove the nut -3- and remove the Heater Support Pump -V488- -1- from the bracket -2-.

-- Press 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 wire -2- upward.

-- Remove the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Position the :T10359/3 on the :T10359A from above and secure it.

Fig 24: Identifying Engine/Gearbox Jack Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the :T10359/2 onto the engine bracket with the securing element -A- from the :3282 .

-- Position the :T10359A on the :VAS6931 and bring it into position with the engine/transmission assembly.

-- After the :T10359A is positioned correctly, install the bolt -A- with the spacer sleeve on the :T10359A .

Fig 25: Identifying Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Completely 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 installed.

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

Fig 28: Identifying Engine Jack

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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