Engine, Removing

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Due to the factory coating on the cylinder walls, it is imperative the cylinders are NOT honed during any repair!

Special tools and workshop equipment required

Torque wrench (5-50 Nm) VAG 1331
Torque wrench (40-200 Nm) VAG 1332
Engine and transmission jack VAG 1383A
Spring type clip pliers VAS 5024A
Step ladder VAS 5085
Engine and transmission support T10012
Drip tray for VAS 6100 VAS 6208

For information on securing the engine to the engine stand, refer to ENGINE, SECURING ON ASSEMBLY STAND .

NOTE:

To perform this procedure, the ground cable must be disconnected from the battery. Check whether 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 open when removing the engine, must be replaced in the same position when installing engine.

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

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 or vacuum) and electrical wires 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.

Removing

-- With the ignition off, disconnect the battery ground cable. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Remove the engine cover/upper air filter housing. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .

-- Remove the battery. Refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Removal and Installation .

-- Remove the cover -1- for the E-box and remove the wire -2-.

Fig 1: Identifying Cover Of E-Box, Wire & Bolts

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-- Remove the battery holder bolts -arrows- and battery holder.

-- Remove the oxygen sensor (before catalytic converter) electrical connector -arrow- out of the bracket, disconnect the connector and free up the wiring harness.

Fig 2: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

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-- Remove the plenum chamber bulkhead. Refer to Removal and Installation .

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

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

Fig 3: Identifying Pass-Through For Engine Wiring Harness

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-- Open the brackets -arrows- for the wiring.

Fig 4: Routing/Removing Engine Wiring Harness To Control Module Beneath And At Left (In Direction Of Travel) Of Wiring Harness

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-- Remove the engine wiring harness to control module -1- wiring.

-- Open the brackets -2 and 3- for the wiring.

Fig 5: Identifying Wiring Brackets & Wiring Harness Connector

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-- Expose the harness electrical connector -1- at the left front of the wiring harness and disconnect it.

-- Remove the engine wiring harness to control module wiring.

-- Disconnect all harness electrical connectors of the engine wiring harness/body and set the engine wiring harness on the engine.

-- Disconnect the backup lamp switch electrical connector -4-.

Fig 6: Identifying Back-Up Light Switch Electrical Harness Connector, Ground (GND) Wire & Starter Wires

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-- Remove the nut -3- and remove the ground wire.

-- Disconnect the electrical connector -1-, remove the nut -2- and remove the wire from the starter.

-- Free up the wires.

-- Disconnect the vacuum hose -arrow- from the brake booster.

Fig 7: Disconnecting Vacuum Hose From Brake Booster

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With a Manual Transmission

-- Remove the shift mechanism from the transmission. Refer to SHIFT MECHANISM .

-- Remove the hose/pipe assembly from the slave cylinder, see the transmission removal procedure in REMOVING .

CAUTION:

Do not operate the clutch pedal any more.

With a DSG Transmission

When touching metal parts, it is possible that an electrostatic discharge could occur. The reason for this is the electrostatic charge of the human body. This charge can lead to functional problems by touching the electrical components of the transmission and selector lever mechanism.

-- Touch a grounded object, for example, a water pipe or a vehicle hoist, before working on the mechatronic unit.

Fig 8: Electrical Warning

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-- Do not make direct contact with the electrical connector terminals.

-- Turn the bayonet connection -1- of the connector toward the left and pull the connector off from the transmission.

Fig 9: Disconnecting Direct Shift Gearbox (DSG) Mechatronic J743 Electrical Harness Connector By Rotating Counterclockwise

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-- Release the lock washer -A- and remove upward.

Fig 10: Identifying Adjustment Screw & Lock Washers

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-- Pull off the lock washer -B- upward.

-- Press off the selector lever cable from selector lever and set it on top.

WARNING:

The fuel supply line is under pressure. Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before disconnecting, wrap a cloth around the connection. Then release the pressure by carefully disconnecting the connection.

-- Mark the hoses -1, 2 and 3- and remove them from the lines.

Fig 11: Identifying Fuel Supply Line Hoses & Charge Air Line

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-- Disconnect the charge air pipe -4-.

-- Drain the cooling system. Refer to DRAINING AND FILLING .

-- Disconnect the coolant hoses -1 and 2-.

Fig 12: Disconnecting Coolant Hoses

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-- Slightly loosen the engine mount to engine mount bracket bolts -arrows- (loosen less than 1 rotation).

Fig 13: Identifying Subframe Mount/Engine Bracket Bolts

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-- Slightly loosen the transmission mount to transmission mount bracket bolts -arrows- (loosen less than 1 rotation).

Fig 14: Identifying Removal Of Assembly Mounting On Transmission Side From Transmission Bracket

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-- Remove the charge air hoses -arrows-.

Fig 15: Disconnecting Charge Air Hoses

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-- Bring the lock carrier into the service position. Refer to Description and Operation .

-- For better positioning, place a approximately 80 mm long sleeve, for example, the specialty socket wrench3353, socket 19 mm3077 or a sleeve from the holding fixtureVW 540/1A (old tool) on the right and left sides between the lock carrier and the body.

Fig 16: Identifying Specialty Socket Wrench 3353, Socket 19 mm 3077 Between Lock Carrier And Body

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-- Remove the front part of the left wheel housing liner. Remove the bolts -1 through 3- to do so.

Fig 17: Identifying Removal Of Left And Right Front Part Of Wheel Housing Liner

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-- Remove the auxiliary coolant pump bracket bolts -arrows- and disconnect the electrical connector.

Fig 18: Identifying Removal Of Coolant Pump V50

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-- Disconnect coolant hoses -arrows- from the heater core at the bulkhead.

Fig 19: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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With Air Conditioning

-- Remove the intake air guide with coolant fans. Refer to COOLANT FAN AND COOLANT FAN 2 .

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

-- Remove the A/C compressor from the accessory bracket. Refer to Removal and Installation .

-- Secure the A/C compressor -3- to the lock carrier -2- as shown. Place some cardboard -1- against the radiator to protect it.

Fig 20: Securing A/C Compressor To Lock Carrier

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NOTE:

To prevent damage to condenser and also to the refrigerant lines/pipes, ensure that the pipes and hoses are not stretched, kinked or bent.

-- Remove the bolts -arrows- for the coolant pipe and oil dipstick guide tube from the intake manifold and pull the oil dipstick guide tube upward from the engine.

Fig 21: Disconnecting Coolant Pipe And Oil Dipstick Guide From Intake Manifold And Pulling Off Oil Dipstick Guide Upward From Engine

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-- Disconnect the generator electrical connector -2-.

Fig 22: Identifying Connector, Electrical Wire And Wiring Clamp On Generator

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-- Remove the generator nut -1-, wire and wire clamp nut -3-.

-- Disconnect the electrical connector -1-.

Fig 23: Identifying Connector & Wire Behind Coolant Pipe

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-- Free up the wire -2- behind the coolant pipe -3-.

-- Disconnect the electrical connector -1-.

Fig 24: Identifying Connector, Cable Brackets & Wires

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-- Open the cable brackets -2 and 3- and free up the wires.

-- Remove the throttle valve control module. Refer to THROTTLE VALVE CONTROL MODULE .

-- Remove the intake air temperature sensor, -item 23- in the INTAKE MANIFOLD ASSEMBLY OVERVIEW .

-- Disconnect the electrical connector from the turbocharger recirculating valve.

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

Fig 25: Installing Protective Cap For Drive Axle On Engine

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

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

-- Remove the pendulum support bolt -1-.

Fig 26: Identifying Pendulum Support & Bolts

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-- Remove the pendulum support bolts -2 and 3- and remove the pendulum support.

-- Disconnect/unclamp all remaining electrical wires required, from the engine/transmission assembly and set aside.

-- Disconnect all other coolant, vacuum and intake hose connections, as necessary from the engine.

-- Install the T10012 to the VAG 1383A.

-- Position the T10012 on the engine as shown and tighten the bolt -1- and nut -2-.

Fig 27: Attaching Engine Support T10012 On Engine

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Tightening specification: 20 Nm.

-- Gently lift the engine and transmission using the VAG 1383A.

Use the VAS 5085 to remove engine and transmission mount bolts.

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

Fig 28: Identifying Subframe Mount/Engine Bracket Bolts

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

Fig 29: Identifying Removal Of Assembly Mounting On Transmission Side From Transmission Bracket

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NOTE:

A 2nd technician is needed to lower the engine/transmission assembly.

The engine/transmission assembly must be guided with care to prevent damage while lowering.

When lowering, be especially careful of the A/C compressor and turbocharger.

-- Only lower the engine/transmission assembly slightly, then pull forward as far as possible, turn to the left and continue lowering.