Engine, Removing

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

Special tools and workshop equipment required

Pry Lever-Rmv Outside Mirror -80-200-
Engine Sling -2024 A-
Engine-/Gearbox Jack -V.A.G 1383 A-
Hose Clip Pliers -V.A.G 1921-
Hose Clip Pliers -VAS 6362-
Step Ladder -VAS 5085-
Engine Bung Set -VAS 6122-
Drip Tray for -VAS 6100- -VAS 6208-
Engine Support -T10359-

NOTE:

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

The engine is removed downward 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.

CAUTION:

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

Route all lines and wires in their original locations.
Ensure sufficient clearance to all moving or hot components.

-- Check the Diagnostic Trouble Code (DTC) memories of all control modules. Refer to the vehicle diagnostic tester.

-- Disconnect the battery ground cable with the ignition turned off. Refer to Removal and Installation .

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

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

-- Remove the battery, the battery tray bolts -arrows- and tray.

Fig 1: Identifying Battery Holder Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Remove the wiper arms. Refer to WIPER ARMS .

-- Remove the plenum chamber cover. Refer to one of the following:

GTI (2008 through 2009), Eos, and Passat. Refer to Description and Operation .
Tiguan and CC. Refer to Description and Operation .
GTI (from 2010). Refer to Description and Operation .

GTI and Eos

-- Remove the plenum chamber bulkhead. Refer to Description and Operation .

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

Engine Control Module -J623-, GTI (2008 THROUGH 2009) AND EOS THROUGH 11.08 .

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

Passat and CC

Tiguan

Continuation for all Vehicles

Fig 2: Identifying Pass-Through For Engine Wiring Harness

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

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

Fig 3: Identifying E-Box Cover And Latches

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

Fig 4: Identifying Generator Cable -A- And Battery Cable -B-

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

Fig 5: Identifying Ground (GND) Cable On Longitudinal Member

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

Fig 6: Identifying Locking Mechanisms Of Cable Guide On Longitudinal Member

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

Fig 7: 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.

Vehicles with a Manual Transmission

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

-- Pinch off the hose from the master cylinder using the hose clamps up to 25 mm dia. -3094-.

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

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

Fig 9: Identifying Clip

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-- Pull the line out of the breather/slave cylinder and seal it off.

CAUTION:

Do not press the clutch pedal.

Vehicles with a Automatic Transmission

-- Remove the selector lever cable from the transmission. Refer to [For transmission(s) 09G] [For engine(s) CCTA] Removal and Installation .

Vehicles with a Direct Shift Gearbox (DSG R)

-- Remove the selector lever cable from the transmission. Refer to SELECTOR LEVER HANDLE .

Tiguan, with a Automatic Transmission

-- Remove the transmission oil cooler lines from the transmission. Refer to [For transmission(s) 09G] [For engine(s) CCTA] Description and Operation .

Continuation for all Vehicles

-- Disconnect the connector -2-.

Fig 10: Identifying Protective Boot Cable Tie, Electrical Connector And Ground Cable

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

Fig 11: Identifying Harness Connector And Fan Mount Mounting Bolts

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-- Loosen the hose clamp -2-.

Fig 12: Identifying Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

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-- Remove the bolt -4-.

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

WARNING:

The coolant system is under pressure when the engine is warm.

Risk of scalding due to hot steam and hot coolant.

Reduce pressure by covering the coolant expansion tank cap with a cloth and open carefully.

-- Open the coolant expansion tank cap.

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

-- Remove the front part of the wheel housing liner or the entire front wheel housing liner. Refer to Description and Operation .

-- Remove the charge air hoses -arrows-.

Fig 13: Identifying Charge Air Hoses

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

Fig 14: Identifying Harness Connector And Fan Mount Mounting Bolts

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-- Remove the fan shroud downward.

-- 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

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-- Disconnect the electrical connector -2- for the engine coolant temperature sensor on radiator outlet -G83-.

Fig 16: Identifying ECT Electrical Connector

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NOTE:

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

-- Place the drip tray for -VAS 6100- -VAS 6208- under the engine.

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

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

Fig 17: Identifying Coolant Hoses

Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING:

The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure.

-- Disconnect the lines from the fuel transfer.

Fig 18: Identifying Breather Line, Vacuum Line & Fuel Supply Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vent line -1-

Vacuum line -2-

Fuel supply line -3-

GTI, Eos, Passat and CC

Fig 19: Identifying Radiator Upper Coolant

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-- Remove the upper coolant hose -arrow- from the radiator.

Tiguan

-- Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.

Continuation for all Vehicles

Fig 20: Identifying Heat Exchanger Coolant Hoses

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-- Disconnect the coolant hoses leading to the heater core -arrows-, to do this slightly pull the securing clip.

-- From above, remove the nuts -arrows- for the front exhaust pipe to the turbocharger.

Fig 21: Identifying Front Exhaust Pipe/Turbocharger Nuts

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-- Disconnect the vacuum hoses -arrows-.

Fig 22: Identifying Vacuum Hoses

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Vehicles with Front Wheel Drive (FWD)

Fig 23: Identifying Drive Axle Heat Shield Bolts And Shield

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

Continuation for all Vehicles

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

CAUTION:

Risk of destroying due to a reversed running direction on a used ribbed belt.

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

-- To release the tension on the ribbed belt, rotate the belt tensioner in the -direction of the arrow- from underneath.

Fig 24: Identifying Wrench And Locking Pin -T10060 A-

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-- Secure the tensioner using the locking pin -T10060 A-.

-- Remove the ribbed belt.

-- Disconnect the connector -1- from the A/C compressor regulator valve -N280-.

Fig 25: Identifying A/C Compressor Bolts And Solenoid Clutch Electrical Connector

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WARNING:

Refrigerant can cause serious personal injury.

Do not open the Air Conditioning (A/C) refrigerant circuit.

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

CAUTION:

Risk of damaging refrigerant lines and hoses.

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

-- Secure the compressor, with the refrigerant lines attached, to the longitudinal member.

GTI and Eos

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

Continuation for all Vehicles

Fig 26: Identifying After-Run Coolant Pump V51 Bracket Bolt -2-

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

NOTE:

The after-run coolant pump -V51- stays in the installed position.

-- First, remove the bolt -1- then the bolts -2 and 3- and then remove the pendulum support.

Fig 27: Identifying Support Bracket, Pendulum And Bolts

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

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

-- Install the engine support -T10359- -1- to the engine and guide it into the mount.

Fig 28: Identifying Engine Support With Additional Supports

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Set the support -3- in order to prevent the engine from tilting out of the engine support -T10359-.

-- Secure the engine support -T10359- -1- to the cylinder block using the bolt -3-. Tighten to approximately 20 Nm.

Fig 29: Identifying Engine Support And Threaded Hole Location

Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:

The threaded hole for the bolt -1- serves to secure the after-run coolant pump -V51-.

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

-- Slightly lift the engine and transmission.

NOTE:

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

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

Fig 30: Identifying Engine Mount To Engine Mount Bracket Bolts

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

Fig 31: Identifying Engine Mount To Engine Mount Bracket Bolts

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NOTE:

Verify that all hose and wire connections between the engine, transmission and body have been disconnected.

To prevent damage, carefully guide the engine and transmission when lowering.

Vehicles with a DSG R

Pay attention to the selector lever cable.

Continuation for all Vehicles

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

Secure the engine to the engine and transmission holder -VAS 6095- when working on it. Refer to ENGINE, SECURING TO Engine and Transmission Holder VAS 6095 .