Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Torque Wrench (5-50 (Nm) (V.A.G 1331)
• Torque Wrench (40-200 Nm) (V.A.G 1332)
• Engine/Transmission Jack (V.A.G 1383 A)
• Spring Type Clip Pliers (VAS 5024 A)
• Step Ladder (VAS 5085)
• Engine/Trans. Support (T10012)
• Cable Tie
For information on securing the engine to the engine stand, refer to => [ Engine, Securing to ] Procedures.
• To perform this procedure, the ground cable must be disconnected from the battery. See if a coded radio is installed. If so, obtain the antitheft code beforehand.
• The engine is removed downward together with the transmission.
• All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine.
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
- Disconnect the battery Ground (GND) cable with the ignition turned off.
- Remove the engine cover/upper air filter housing. Refer to => [ Engine Cover/Upper Air Filter Housing ] Engine Cover/Upper Air Filter Housing.
- Remove the battery, battery tray bolts - arrows - and tray.
GTI and Eos:
- Remove the wiper arms, the plenum chamber cover and the bulkhead plenum chamber.
- Disconnect the engine wiring harness connector from the Engine Control Module (ECM).
- Release the pass-through for the engine wiring harness - arrow - and pull it off upward.
Passat:
- Remove the windshield wiper arms and plenum chamber cover.
- Disconnect the engine wiring harness connector from the ECM.
- Release the pass-through for the engine wiring harness - arrow - and pull it off upward.
Continuation for all Vehicles:
- Remove the nut and the cable - arrow - for the generator from the fuse holder.
- Remove the bolt and the ground wire - arrow - from the longitudinal member.
- Open the locking mechanisms for the cable guide on longitudinal member - arrows -.
- Disconnect all harness connectors of the engine wiring harness/body and set down the engine wiring harness on the engine.
Fuel system is under pressure!
• Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
• Before loosening the line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.
- Disconnect the lines - 1, 2 and 3 -. Press the release buttons.
GTI and Eos:
- Disconnect the ventilation line - 2 -. Remove the Evaporative Emission (EVAP) canister with the hoses upward from the bracket.
Continuation for all Vehicles:
- Remove the noise insulation.
- Remove the left and right front part of the front wheel housing liners.
- Disconnect the charge air hoses - arrows -.
- Remove the right drive axle heat shield bolts - arrows - and shield.
- Remove the right and left drive axles.
- Remove the front pipe with catalytic converter. Refer to => [ Front Exhaust Pipe with Catalytic Converter ] Service and Repair.
- Move the lock carrier into the service position.
- Drain the coolant. Refer to => [ Draining and Filling ] Procedures.
- Evacuate the Air Conditioning (A/C) system.
- Disconnect the A/C line - arrow - from the A/C compressor.
- Remove the A/C pipe from the condenser - arrow -.
- Remove the bolts - 1 through 3 - and remove the pendulum support.
- Disconnect all remaining electrical wires necessary from the engine/transmission and set them aside.
- Disconnect all coolant, vacuum- and intake hose connections from the engine.
Vehicles with a Manual Transmission:
- Remove the shift mechanism from the transmission.
- Clamp off the hose/line assembly hose - A - to the slave cylinder using the hose clamps up to 25 mm dia. (3094).
- Pull the hose/line assembly clip - arrow - out as far as the stop.
- Remove the hose/line assembly from the slave cylinder breather.
Do not operate the clutch pedal any more.
Vehicles with a Automatic Transmission:
- Remove the selector lever cable from the transmission.
Vehicles with a Direct Shift Gearbox:
- Disconnect the selector lever cable from the transmission.
Continuation for all Vehicles:
- Remove the coolant recirculation pump (V50) bolts - arrows -.
- Install the engine/trans. support (T10012) to the engine/transmission jack (V.A.G 1383 A).
- Install the engine/trans. support (T10012) to the engine as illustrated and tighten the bolt - 1 - and nut - 2 - to 20 Nm.
- Gently, lift the engine and transmission using the engine/transmission jack (V.A.G 1383 A).
- Remove the engine mount to engine mount bracket bolts - arrows -.
- Remove the transmission mount to transmission mount bracket bolts - arrows -.
• Use the step ladder (VAS 5085) to remove the bolts.
• Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.
- Carefully lower the engine with the transmission.