Engine, removing

NOTE: During the following procedure the battery Ground strap must be disconnected. Check whether a coded radio is installed. Obtain the radio code first, if necessary.

The engine is removed in a downward direction together with the transmission.

CAUTION:

When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE: All cable ties which are opened or cut open when removing the engine must be replaced in the same position when installing the engine.

With ignition switched off disconnect battery Ground strap.
Remove engine cover.
Remove left and right sound insulation:
Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW

Drain coolant. Refer to Cooling system, draining and filling .
Remove battery and battery retainer.
Refer to BATTERY, REMOVING AND INSTALLING

Observe rules for cleanliness. Refer to Rules for cleanliness .

CAUTION:

Fire Hazard! Do NOT have anything in the area that can ignite fuel!
The fuel system is under pressure! Before opening the system place a cloth around the connection. Then release the pressure by carefully loosening the connection.

Engine codes AEG, AVH, AZG

Fig 1: Identifying Vacuum Hose To Throttle Valve Control Module, Fuel Return Hose & Fuel Supply Hose (AEG, AVH, AZG)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect following hose connections and collect fuel that leaks out with a cloth.

1 - Vacuum hose to Throttle valve control module -J338-

2 - Fuel return hose (with blue markings)

3 - Fuel supply hose (with white markings)

Engine codes BBW, BEV

Fig 2: Disconnecting Fuel Supply Line Off Union By Pressing Locking Ring Into Union

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Disconnect fuel supply line -1- off union by pressing locking ring -2- into union -3-.

Continued for all vehicles

Seal lines to avoid contamination of fuel system.

NOTE: Seal the intake ports in the intake manifold lower section with clean cloths.

In preparation for further disassembly work disconnect connectors from following components (Refer to Component Locations):

Camshaft Position (CMP) sensor -G40-

Fuel Injectors -N30- to -N33-, unclip cable guide

Engine Coolant Temperature (ECT) sensor -G62-

Engine speed (RPM) sensor -G28-

Knock Sensor (KS) 1 -G61-

Knock Sensor (KS) 2 -G66-

Oil pressure switch -F1-

Mass Air Flow (MAF) sensor -G70-

Throttle valve control module -J338-

A/C cut-out thermal switch -F163-

Engine code BBW

Valve -1- for camshaft adjustment -N205-

Ignition coils with power output stages -N70-, -N127-, -N291-, -N292-

Secondary Air Injection (AIR) pump motor -V101-

Engine code AEG, AVH, AZG

Ignition coils (-N- and -N128-) with power output stage -N122-

Secondary Air Injection (AIR) pump motor -V101-

Engine code BEV

Ignition coils with power output stages -N70-, -N127-, -N291-, -N292-

Secondary Air Injection (AIR) pump motor -V101-

Continued for all vehicles

Remove air cleaner. Refer to Air cleaner, disassembling and assembling .
Remove interconnecting, coolant, vacuum and intake hoses on engine.
Remove intake manifold upper part. Refer to Intake manifold upper part, removing and installing .

NOTE: Seal the intake ports in the intake manifold lower part with a clean cloth.

Vehicles with manual transmission

Disconnect shift mechanism from transmission.
Refer to GEAR SELECTOR MECHANISM UP TO 05.99, SERVICING or GEAR SELECTOR MECHANISM FROM 05.99, SERVICING

Remove hydraulic clutch slave cylinder:

Refer to 34 MANUAL TRANSMISSION - CONTROLS, HOUSING

NOTE: The clutch pedal must not be operated.

Vehicles with automatic transmission

Disconnect selector lever cable from transmission:
Refer to SELECTOR CABLES, REMOVING AND INSTALLING

Continued for all vehicles

Remove poly V-belt. Refer to Poly V-belt, removing and installing .
Remove securing clamps for power steering pressure line.
Remove power steering pump from bracket and lay to side; hoses remain connected:

Refer to POWER STEERING PUMP WITH HYDRAULIC LINES/HOSES, OVERVIEW

Vehicles with air conditioning

Remove air conditioning compressor.
Note additional information and removal work. Refer to Additional information and assembly work on models with an air conditioning system .

Continued for all vehicles

Disconnect hoses from engine.
Vehicles with secondary air pump: remove secondary air pump motor and bracket.
Disconnect all electrical wiring from transmission, Generator and starter and move clear.
Disconnect all other electrical connections from engine and lay to one side as necessary.

Fig 3: Identifying Pendulum Support & Bolts

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Unbolt pendulum support (arrows).
Remove protective cover for right side inner constant velocity joint from engine.
Remove right axle shaft and disconnect left axle shaft at transmission:
Refer to FRONT DRIVE SHAFTS, SERVICING

Remove front exhaust pipe. Refer to Exhaust system components, removing and installing .
Disconnect connector for oxygen sensor before catalytic converter and move wiring clear. Refer to Exhaust system components, removing and installing .
Depending on version, remove oil pan protection. Refer to Oil pan, removing and installing , and remove rubber bushings. Refer to Engine code BBW, assembly overview , Fig.13 .
Insert engine bracket T10012 in engine/transmission jack V.A.G 1383 A.

Fig 4: Identifying Engine Bracket T10012 & Engine/Transmission Jack V.A.G. 1383A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure engine bracket T10012 to front of cylinder block with securing bolt M10 x 25(8.8) to 40 Nm.
Tighten securing nut on exhaust side hand tight.
Lift engine and transmission lightly using engine/transmission jack V.A.G 1383 A.

Fig 5: Locating Engine Carrier Bolts (Engine Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt engine side of assembly mounting from top of engine carrier (arrows).

NOTE: Use step ladder VAS 5085 or equivalent to remove securing bolts.

Fig 6: Locating Engine Carrier Bolts (Transmission Side)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt transmission side of assembly mounting from top of transmission carrier (arrows).
Carefully lower engine with transmission.

NOTE: Engine and transmission must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines/wiring.