Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Engine and Gearbox Jack: VAS6931
Engine/Gearbox Jack - Engine Support: T10359A
Engine/Gearbox Jack - Pin: T10359/2
Adapter: T10359/3
Securing element from the Transmission Support: 3282
Pry Lever: 80-200
Locking Pin: T10060A
Protective Eyewear
Safety Gloves
Step Ladder

Procedure

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

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.

-- Open the coolant reservoir cap -arrow-.

Fig 1: Identifying Coolant Reservoir Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 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 air duct pipe -5- downward.

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

Fig 3: Identifying Vacuum Pump

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-- 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 4: Identifying Heater Core Hoses

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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 FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

Vehicles with Secondary Air System

Fig 5: Locating Release

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Continuation for All Vehicles

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

Fig 6: 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-.

-- 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 7: Identifying Battery Cables

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Vehicles with Secondary Air System

Fig 8: Identifying Connecting Pipe And Connector

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

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

Fig 9: Identifying Brackets And Clips

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-- 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 10: Locating Connectors

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

-- Disconnect and remove the connectors -arrow-.

Fig 11: Identifying Bracket

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

-- Remove the selector lever cable from the transmission. Refer to OVERVIEW - SELECTOR MECHANISM .

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 12: 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 13: Identifying Engine Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 14: Identifying Transmission Mount Bolts

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

Fig 15: 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 16: 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 .

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

Fig 17: Identifying After-Run Coolant Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 18: Identifying Coolant Hose Release

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

Fig 19: Identifying Bracket

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

Fig 20: Identifying Bracket Bolt

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

Fig 22: 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- from the engine mount -2-.

Fig 23: Identifying Engine Mount Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -2- completely.

Fig 24: Identifying Transmission Mount Bolts

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NOTE:

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

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