Engine, Removing

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

Special tools and workshop equipment required

Engine and Gearbox Jack :VAS6931

Fig 1: Engine and Gearbox Jack VAS6931 or VAG1383A
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Engine/Gearbox Jack - Engine Support :T10359A

Fig 2: Identifying Engine/Gearbox Jack Engine Support
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Engine/Gearbox Jack - Pin :T10359/2
Adapter :T10359/3
Securing element from the Transmission Support :3282

Fig 3: Identifying Transmission Support 3282
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Pry Lever :80-200

Fig 4: Identifying Pry Lever
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
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 5: Identifying Coolant Reservoir Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

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

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

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

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

-- Disconnect the connector -1-.

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

Fig 6: Component Location Engine Coolant Temperature Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Allow the coolant to drain.

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

-- Remove the bolts -1 and 3-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Release the catch in direction of -arrow- and remove the cover -2-.

-- Free up the coolant hose -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the catches in direction of -arrows- and remove the upper air duct -1-.

-- Disconnect the vacuum hose -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamp -2- and remove the air duct hose.

-- Remove the air filter housing -3-.

-- Remove the bolt -arrow- on the left and right.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the vacuum hose -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Vehicles without Parking Heater:

Fig 7: Identifying Heater Core Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Continuation for All Vehicles:

Fig 8: Exploded View Of Heated Oxygen Sensor

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -1 and 2- and remove them from the bracket. Free up the wires.

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

Fig 9: Catalytic Converter - Tightening Sequence

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nuts -1 and 3-.

NOTE:

The installation position is shown in the illustration with the engine removed for clarity.

Ignore -item 4-.

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-.

Fig 10: Identifying Expansion Tank

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 11: Identifying Clamp And Upper Left Coolant Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

Fig 12: Free Electrical Wiring Up To Generator Using 80-200

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Free up the wires.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Manual Transmission:

Fig 13: Identifying Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 14: Identifying Park/Neutral Position Switch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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 Hose Clamps - Up To 25mm :3094 .

Fig 15: Clamping Off Hose/Line Assembly Hose To Slave Cylinder With Hose Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- 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.

-- 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 -4- for the Dual-Clutch Transmission Mechatronic -J743-. To do so, turn the twist lock counter-clockwise.

Continuation for All:

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

Fig 16: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Open the clamp -1 and 2- and remove the air duct hose.

Fig 17: Identifying Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the air duct pipe. Refer to AIR DUCT PIPE FROM CHARGE AIR COOLER TO INTAKE MANIFOLD, REMOVING AND INSTALLING .

Fig 18: Disconnect Charge Air Pressure Sensor Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles with Parking Heater:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Continuation for All Vehicles:

Fig 19: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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.

-- 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 Locking Pin :T10060A .

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-.

Fig 20: 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 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.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Fasten the Adapter Adapter :T10359/3 on the Engine/Gearbox Jack - Engine Support :T10359A as shown.

Fig 21: Identifying Engine/Gearbox Jack Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the Pin Engine/Gearbox Jack - Pin :T10359/2 onto the engine bracket with the securing element -A- from the Transmission Support :3282 .

-- Place the Engine/Gearbox Jack - Engine Support :T10359 in the Engine and Gearbox Jack :VAS6931 .

-- Position the Engine/Gearbox Jack - Engine Support :T10359A on the cylinder block. Fasten the bolt -A- with the spacer sleeve on the cylinder block. Tightening specification 20 Nm.

Fig 22: Identifying Engine Support

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 23: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 24: 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 -arrow 2-.