Engine, Removing

Special tools and workshop equipment required

Engine and Gearbox Jack :VAS6931
Engine/Gearbox Jack - Engine Support :T10359 A
Engine/Gearbox Jack - Pin :T10359/2
Adapter :T10359/3
Securing element from the Transmission Support :3282
Pry Lever :80-200
Protective Eyewear
Safety Gloves
Step Ladder

NOTE:

The engine with transmission is removed downward. For this reason it is necessary to remove the subframe.

Procedure

Fig 1: Identifying Coolant Reservoir Cap

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CAUTION:

The cooling system may be under pressure. There is a 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 suitable towel and carefully opening it.

-- Open the coolant reservoir cap -arrow-.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

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

-- Disconnect the connector -1-.

Fig 2: Component Location Engine Coolant Temperature Sensor

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-- Place the Shop Crane - Drip Tray :VAS6208 underneath.

-- Lift the clamp -3- and remove the lower right coolant hose from the radiator and drain the coolant.

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

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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-- Engine compartment battery: remove the battery tray -1-. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Luggage compartment battery: remove the air filter housing mount.

-- Disconnect the vacuum hose -2-.

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-- Press the release button on the vacuum hose -1- and remove the hose from the vacuum pump.

Vehicles without Parking Heater:

Fig 3: Identifying Heater Core Hoses

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

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

Vehicles with Parking Heater:

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-- Loosen the hose clamp -1-, lift the clamps -arrows- and remove the coolant hoses.

Continuation for All Vehicles:

Fig 4: Heated Oxygen Sensors

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-- Remove the connectors -1 and 2- from the bracket and disconnect them. Then free up the wires.

-- Loosen the clamp -1- for the catalytic converter -2- and push the clamp on the turbocharger.

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Fig 5: Identifying Expansion Tank

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CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

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

-- Remove the screw -arrow-, if applicable.

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-- Loosen the hose clamps -1 and 2- and remove the coolant hoses.

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

Fig 6: Identifying Clamp And Upper Left Coolant Hose

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NOTE:

Use the :80 - 200 for removing the spiral clips in the following steps.

Fig 7: Free Electrical Wiring Up To Generator Using 80-200

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Golf, Passat and Arteon:

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-- Disconnect the connector -1- from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

-- Remove the connectors -2 and 3- from the bracket and disconnect.

-- Free up the wires.

-- Release the retainers -arrows- and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver -arrow-, remove the cover -1- for the engine compartment E-box upward.

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

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Sharan:

Fig 8: Identifying Open Wiring Router Bracket And Locating Cable Ties

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-- Release and disconnect the connector from the Engine/Motor Control Module -J623-. Refer to Engine/Motor Control Module -J623-, REMOVING AND INSTALLING .

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

-- Release and disconnect the connectors -1- and -2-.

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-- Release the wiring guide locking mechanisms -arrows- and place the engine wiring harness -3- on the engine.

-- Free up the wires.

-- Secure the wires to the engine with a cable tie.

-- Release the retainers -1- in the direction of the -arrow- and remove the cover -2- for the engine compartment E-box.

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

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Vehicles with Manual Transmission:

Fig 9: Identifying Connector

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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.

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- Disconnect the left front connectors from the transmission:

Fig 10: Identifying Park/Neutral Position Switch

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

-- Remove the shift and selector cable from the transmission, remove the cable bracket and move it to the side with the cables. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

-- Clamp the hose/line assembly -A- to the slave cylinder with the :3094 .

Fig 11: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

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-- Pull hose/line assembly clip -arrow- out as far as stop.

-- Remove pipe/hose line assembly from the slave cylinder ventilator.

Vehicles with Dual-Clutch Transmission:

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-- Disconnect the connector -1-.

-- Push the B+ terminal protector -3- back and disconnect the B+ wire from the starter solenoid switch.

-- Loosen the nut -arrow- and remove the ground wire.

NOTE:

Depending on the version the ground cable is attached to the starter bolt.

-- To discharge static electricity, touch a ground by hand (without gloves).

-- Do not touch connector terminals in the transmission connector with hands.

-- Disconnect the connector -2- for the Dual-Clutch Transmission Mechatronic -J743- by turning the twist lock counter-clockwise.

-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

Vehicles with Automatic Transmission:

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-- Pry the selector lever cable -1- off the selector lever -2-, for example, using an open end wrench.

-- Remove the connector -6- from the Multifunction Transmission Range Switch -F125- and free up the wire on the bracket.

-- Remove the bolts -5- from the cable bracket -4-. Do not remove the lock washer -3-.

-- Disengage the selector lever cable -1- from the clip -arrow-.

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NOTE:

Do not bend or kink the selector lever cable.

So that the cable is not damaged when removing and installing the transmission, secure the cable using for example a cable tie on a suitable location on the body.

-- Remove the connector from the transmission as follows. Push the retainer -1- in the direction of the arrow, open the bracket -2- and then remove the connector -3- from the transmission.

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-- Disconnect the connections from the starter. Refer to STARTER, REMOVING AND INSTALLING .

Continuation for all:

Fig 12: Identifying Bolts

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

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

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-- Loosen the hose clamps -arrows- and remove the left charge air hose -A-.

Fig 13: Removing Change Air Hose

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-- Disconnect the radiator fan connector -1- by sliding the retainer back in the direction of the arrow -A- and pressing the release downward.

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-- Press the left and right fan shroud -B- locking tabs evenly. Disengage the fan shroud and remove downward from the radiator.

-- Loosen the hose clamp -1- and -2- and remove the right charge air hose.

Fig 14: Identifying Clamps

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-- Seal the open lines and connections with clean plugs from the :VAS6122 .

-- Cover the radiator with the :VAS531003 .

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-- Free up the coolant hose -3-.

Fig 15: Disconnect Charge Air Pressure Sensor Connector

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-- Remove the bolts -arrows-.

-- Loosen the hose clamp -2-.

-- Disconnect the connector -1- from the Charge Air Pressure Sensor -G31-.

-- Remove the air duct pipe.

Vehicles with Parking Heater:

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-- Loosen the clamp -1-, remove the bolt -2- and remove the parking heater muffler.

Continuation for All Vehicles:

Fig 16: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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

-- Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioner. If necessary, remove the :T10060A .

Fig 17: Identifying A/C Compressor Components

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CAUTION:

There is a risk of getting frostbite from the 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 and tie up to the right side. While doing so, do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the left and right drive axles from the flange shafts. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Tie up the drive axles to the rear.

NOTE:

Be careful not to damage the protective coating on the drive axle.

-- If equipped, release the connector for the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- -a- and remove the connector -b-.

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Vehicles with Front Axle Differential Lock

Fig 18: Locating Axle Differential Lock Control Module Connector

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-- Disconnect the connector -arrow- for the Differential Locks Control Module -J647-.

AWD Vehicles:

Fig 19: Driveshaft Heat Shield

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-- Remove the bolts -A- and -B- on the bevel box and remove the heat shield -1-.

-- Mark the position of the driveshaft with the flexible disc to the bevel box output flange -arrows-.

Fig 20: Mark Position Of Driveshaft

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-- Remove the driveshaft from the bevel box -arrows-. Refer to DRIVESHAFT, REMOVING AND INSTALLING (1 Of 2) / DRIVESHAFT, REMOVING AND INSTALLING (2 Of 2) .

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-- To loosen or tighten the driveshaft, counterhold at the rear final drive if necessary.

Fig 21: Counterholding Rear Final Drive To Loosen And Tighten Driveshaft

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-- Secure the :T10323 with a bolt in the inside rear threaded hole for the subframe.

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-- A subframe bolt is suitable for this.

-- Place a cloth -A- on the Support Bridge and place the driveshaft on it.

Continuation for All Vehicles:

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-- Remove the nuts -2-.

-- Loosen the clamping sleeve -arrow- and push it toward the rear.

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-- Remove the catalytic converter with the front exhaust pipe.

-- Remove bolt -arrow- and push the bracket for the wiring harness to the side.

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-- Fasten the :T10359/3 on the :T10359A as shown.

Fig 22: Identifying Engine/Gearbox Jack Engine Support

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

-- Place the :T10359 in the :VAS6931 .

-- Position the :T10359A on the cylinder block. Tighten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 23: Identifying Engine Support

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-- Secure the engine with the support element -B- and lift the engine with the transmission.

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

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

Fig 24: Identifying Bolts

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-- Carefully drain the engine/transmission assembly while doing so check is all vacuum lines or wires between the engine, transmission and body are separated.

Fig 25: Identifying Engine Jack

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