Engine, Removing

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Lifting tackle 2024 A
Engine mount T10012
Holding fixture VW 313
Engine and transmission holder VW 540
workshop crane VAS 6100 or
Shop crane V.A.G 1202 A
Drip tray V.A.G 1306 or drip tray for workshop crane VAS 6208
Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A
Spring-type clip pliers VAS 5024A
Step ladder VAS 5085
Cable tie

NOTE:

To perform work sequence, the ground cable must be disconnected from battery. Check whether a coded radio is installed. If so, obtain anti theft coding beforehand.

The engine is removed downward together with the transmission.

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

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 (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

Procedure

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

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

Fig 1: Identifying Battery Holder Bolts

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-- Remove plenum chamber bulkhead Description and Operation .

-- Remove radiator RADIATOR .

With Manual Transmission

-- Remove the hydraulic clutch slave cylinder. SLAVE CYLINDER .

-- Remove the shift mechanism from the transmission SHIFT MECHANISM

With DSG

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, e.g. a water pipe or a lifting platform, before working on the Mechatronic unit.

Fig 2: Identifying Electrical Warning

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

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

Fig 3: Identifying Bayonet Connection -1- Of Direct Shift Gearbox (DSG) Mechatronic Electrical Harness Connector

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-- Remove the selector lever cable on the transmission SELECTOR LEVER CABLE, THROUGH 02.09 .

-- Disconnect the connector -arrow 1-.

Fig 4: Identifying Connector & Vacuum Hoses

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-- Disconnect the vacuum hoses -arrow 2-.

-- Disconnect vacuum hose -arrow 3- at check valve for brake booster.

Continuation for All

-- Disconnect vacuum hose -arrow- to brake booster at tandem pump.

Fig 5: Identifying Vacuum Hose To Brake Booster Disconnected At Tandem Pump

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

Fig 6: Identifying Coolant Hoses To Heater Core Disconnected At Bulkhead

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-- Unscrew ground (GND) wire nut -1-.

Fig 7: Identifying Removal Of Ground (GND) Wire, Starter Wires & Free Up Cables

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-- Disconnect wires -2- and -3- on starter.

-- Free up the cables.

-- Disconnect connector -arrow- at Engine Coolant Temperature (ECT) sensor -G62-.

Fig 8: Locating Engine Coolant Temperature (ECT) Sensor G62

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-- Pull the release pin -arrow 1- and open the knurled nut -arrow 2-.

Fig 9: Locating Multi-Pin Harness Connector For Pump-Injector Units

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-- Pull off the central connector for pump injector unit and free up the wiring harness.

-- Disconnect connector -arrow- at fuel temperature sensor -G81- and free up the wiring.

Fig 10: Locating Fuel Temperature Sensor G81

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WARNING:

The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
In addition, the fuel system is under pressure! Before opening the system, place rags around the connection area and release pressure by carefully loosening the connection!
Wear protective goggles and protective gloves when working on the fuel system!

-- Mark the hoses -2-, remove them and free them up.

Fig 11: Identifying Bolt And Clips To Remove Air Duct

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-- Remove the connecting hoses and the connecting pipe. To do this, slightly lift the retaining clips -1- and remove the bolts -3- from the lifting eye.

-- Disconnect the fuel supply line -3- and the fuel return line -2-. To do this, pull the release buttons.

Fig 12: Identifying Fuel Supply Line, Fuel Return Line & Coolant Hose

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-- Disconnect the coolant hose -1- from the coolant expansion tank.

-- Only slightly loosen bolts -arrows- of engine mount at engine mount bracket (less than 1 rotation).

Fig 13: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- Only slightly loosen bolts -arrows- of transmission mount at transmission (less than 1 rotation).

Fig 14: Identifying Transmission Side Of Assembly Mounting At Top Of Transmission Carrier

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-- Disconnect connector -arrow- at intake flap motor -V157-.

Fig 15: Identifying Connector Disconnected At Intake Flap Motor V157

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-- Remove connector -arrow- for Camshaft Position (CMP) sensor -G40- from the bracket and disconnect it.

Fig 16: Locating 3-Pin Harness Connector For Camshaft Position (CMP) Sensor G40

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-- Disconnect the connector -arrow- at oil pressure switch -F1-.

Fig 17: Identifying Connector Disconnected At Oil Pressure Switch F1

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-- Unscrew oil pressure switch.

-- Disconnect the connector -arrow- at engine speed (RPM) sensor -G28- with assembly tool T10118.

Fig 18: Identifying Connector Disconnected At Engine Speed (RPM) Sensor G28 With Assembly Tool T10118

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NOTE:

To release the connector without the assembly tool T10118, push the connector against the engine speed sensor and simultaneously lift up on the release tab with a thin wire hook.

-- Remove nut -arrow- and remove wiring bracket from threaded stud.

Fig 19: Identifying Removal Of Nut And Wiring Bracket From Threaded Stud

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-- Free up cable.

-- Disconnect the connector strip from the glow plugs -arrows-.

Fig 20: Identifying Connector Strip Disconnected From Glow Plugs

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-- Free up the wiring harnesses to the body.

With Air Conditioning

NOTE:

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

WARNING:

The air conditioning refrigerant circuit must not be opened.

-- Remove screws -2- and -3- on the refrigerant line brackets.

Fig 21: Identifying Removal Of Screws -2- And -3- On Refrigerant Line Brackets

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To facilitate removal and installation of the engine without having to open the refrigerant circuit:

-- Remove ribbed belt RIBBED DRIVE BELT .

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

-- Secure A/C compressor to lock carrier so that the refrigerant lines/hoses are not burdened.

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

-- Remove right and left drive axles from the transmission Removal and Installation .

-- Remove the front exhaust pipe with the catalytic converter FRONT EXHAUST PIPE .

-- Pull off/disconnect all electrical connections, as necessary, from engine and transmission and lay them aside.

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

-- First unscrew bolt -1-.

Fig 22: Identifying Pendulum Support & Bolts

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-- Unscrew bolts -2- and -3- and remove pendulum support.

-- Set engine/transmission support T10012 into engine/transmission jack V.A.G 1383 A.

Fig 23: Identifying Engine/Trans. Support T10012 Set Into Engine/Transmission Jack V.A.G 1383 A

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NOTE:

The mounting pins must be secured to the engine support T10012 as shown.

-- Fasten the engine support T10012 to cylinder block with bolt M10 x 25/8.8 to approximately 40 Nm.

-- Lift engine and transmission slightly using the engine/transmission jack V.A.G 1383 A.

NOTE:

Use step ladder VAS 5085 to remove mounting bolts.

-- From above, unbolt the engine mount -arrows- from the engine mount bracket on the engine side.

Fig 24: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

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-- From above, unbolt the transmission mount -arrows- from the transmission bracket on the transmission side.

Fig 25: Identifying Transmission Side Of Assembly Mounting At Top Of Transmission Carrier

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NOTE:

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

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

-- Carefully lower the engine with transmission downward.