Engine, Removing

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Tension Strap T 10038
Locking Pin T10060 A
Engine Support T10359
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Engine-/Gearbox Jack V.A.G 1383 A
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Drip Tray for VAS 6100 VAS 6208 or V.A.G 1306
Hose Clip Pliers VAS 6362
Cable Tie

NOTE:

To perform this procedure, the battery ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft 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.

Seal off removed fuel, ventilation and vacuum lines so no dirt enters the system.

Leave the key in the ignition lock to prevent the steering wheel from locking.

CAUTION:

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.

-- Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal.

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

-- Remove the air filter housing. Refer to AIR FILTER HOUSING .

-- Remove the battery and the battery tray. Refer to Removal and Installation .

Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09:

-- Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

-- Disconnect the engine harness connector from the Engine Control Module (ECM). Refer to one of the following:

-- Release the pass-through for the engine harness -arrow- and pull off upward.

Fig 1: Identifying Pass-Through For Engine Wiring Harness

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the E-box cover by sliding both latches in the -direction of the arrow-.

Fig 2: Identifying E-Box Cover And Latches

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nuts and the wire from the generator -A- and the wire from the battery -B- from the fuse holder.

Fig 3: Identifying Generator Cable -A- And Battery Cable -B-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open all the wire guide locking mechanisms -arrows- on the longitudinal member.

Fig 4: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Free up the electrical connector -1- and disconnect it.

Fig 5: Identifying Electrical Connector -1- And Wiring Guide Bracket -2-

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-- Open the underlying wiring guide bracket -2-.

-- Remove the ECM wiring harness out of the wiring router and lay it on the engine.

GLI from MY 12:

-- Remove the E-box cover -arrows- inside the engine compartment.

Fig 6: Identifying Engine Control Module (E-Box) Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut and the wire -2- and free it up.

Fig 7: Identifying ECM Connector

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Vehicles with a Manual Transmission:

-- Remove the shift mechanism from the transmission. Refer to [For transmission(s) 02Q] SHIFT MECHANISM .

-- Use hose clamps up to 25 mm dia.3094 to pinch off the hose leading to the clutch master cylinder.

Fig 8: Identifying Use Of Hose Clamps 3094 On Supply Hose To Master Cylinder

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the clip -arrow- for the line -A- out, up to the stop.

Fig 9: Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the line -A- from slave cylinder breather and seal it off.

CAUTION:

Do not operate the clutch pedal any more.

Vehicles with Direct Shift Gearbox (DSG):

-- Disconnect the selector lever cable from the transmission. Refer to [For transmission(s) 02E] SELECTOR LEVER CABLE, THROUGH 02.09 .

Continuation for all Vehicles:

-- Remove the bolt and the ground wire -arrow- from the longitudinal member.

Fig 10: Ground (GND) Cable On Longitudinal Member

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2-.

Fig 11: Identifying Protective Boot Cable Tie, Electrical Connector And Ground Cable

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-- Remove the fan shroud upper bolts -upper arrows-.

Fig 12: Disconnecting Electrical Harness Connector And Removing Mounting Bolts Of Intake Air Elbow

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the hose clamp -2-.

Fig 13: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -4-.

-- Disconnect the electrical connector -arrow- and free up the electrical wire.

WARNING:

Risk of scalding due to hot steam and hot coolant:

The coolant system is under pressure when the engine is warm.
Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the cap on the coolant expansion tank.

-- Remove the front wheels.

-- Remove the noise insulation. Refer to Description and Operation .

-- Remove the front part of the wheel housing liners and/or the front wheel housing liners. Refer to Removal and Installation .

-- Remove the charge air hoses -arrows-.

Fig 14: Disconnecting Charge Air Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -1- and remove the charge air pipe downward.

Fig 15: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the electrical connector -1- and remove the lower fan shroud bolts -lower arrows-.

Fig 16: Disconnecting Electrical Harness Connector And Removing Mounting Bolts Of Intake Air Elbow

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fan shroud downward.

-- Disconnect the connector -2- from the engine coolant temperature sensor on radiator -G83-.

Fig 17: Identifying ECT Electrical Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Collect the leaking coolant in a clean container for disposal or reuse.

-- Place the drip tray for VAS 6100 VAS 6208 or V.A.G 1306 under the engine.

-- Drain the coolant. Refer to DRAINING AND FILLING .

-- Reposition the clamps -1 and 2- and disconnect the coolant hoses.

Fig 18: Disconnecting Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the lines and catch any fuel coming out with a cloth.

Fig 19: Identifying Breather Line, Vacuum Line & Fuel Supply Line

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Ventilation line (press the circlip to release the line).
Vacuum line (press the circlip to release the line), if equipped.
Fuel supply line (pull the circlip upward to release the line).

-- Remove the upper coolant hose -arrow- from the radiator by removing the securing clip.

Fig 20: Identifying Radiator Upper Coolant

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the heater core coolant hoses -arrows-.

Fig 21: Disconnecting Coolant Hoses To Heater Core At Bulkhead

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- From the top, remove the front exhaust pipe with catalytic converter to turbocharge nuts -arrows-.

Fig 22: Identifying Front Exhaust Pipe/Turbocharger Nuts

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-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 23: Installing Protective Cap For Drive Axle On Engine

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the drive axles. Refer to Removal and Installation

-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

-- Remove the ribbed belt. Refer to RIBBED BELT .

-- Disconnect the solenoid clutch electrical connector -1- from the A/C compressor.

Fig 24: Identifying A/C Compressor Bolts And Solenoid Clutch Electrical Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING:

Risk of injury from refrigerant:

Do not open the A/C refrigerant circuit.

-- Remove the A/C compressor bolts -arrows-.

CAUTION:

Risk of damaging the refrigerant lines and hoses:

Do not stretch, kink or bend the refrigerant lines and hoses.

-- Tie up the compressor with the refrigerant lines attached to the longitudinal member.

-- Remove the generator -C-. Refer to Removal and Installation .

-- Remove the after-run coolant pump bracket bolt -2-.

Fig 25: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The after-run coolant pump stays in the installed position.

-- First, remove the pendulum support bolt -1-.

Fig 26: Identifying Pendulum Support & Bolts

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-- Then, remove the bolts -2 and 3- and remove the pendulum support.

Fig 27: Identifying Vacuum Hoses

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-- Disconnect the vacuum hoses -arrows-.

-- Disconnect all remaining electrical wires necessary from the engine/transmission and set them aside.

-- Disconnect all coolant, vacuum and intake connections from the engine.

-- Install the engine Support T10359 to the cylinder block using the bolt -1- and tighten it to approximately 20 Nm.

Fig 28: Identifying Engine Support T10359

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

The threaded hole for the bolt -1- secures the after-run coolant pump.

-- Install the engine-/gearbox jack V.A.G 1383 A to the engine Support T10359.

-- Slightly lift the engine/transmission assembly.

NOTE:

Use the step ladder VAS 5085 to remove the engine/transmission mount bolts.

-- Remove the engine mount to engine mount bracket bolts -arrows-.

Fig 29: Identifying Engine Mount Bolts

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Vehicles with a Manual Transmission:

Fig 30: Identifying Bolts For Subframe Mount At Transmission

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Vehicles with DSG:

Fig 31: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Continuation for all Vehicles:

NOTE:

Verify that all hoses and lines between the engine, transmission and body have been disconnected.

While lowering, carefully guide the engine/transmission assembly in order to prevent damages.

Vehicles with DSG:

-- Pay attention to the selector lever cable.

Continuation for all Vehicles:

-- Pull the engine/transmission as far as possible to the front and left and slowly lower it.

Secure the engine to the engine/transmission holder VAS 6095 whenever working on it; refer to ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095 .