Engine, Removing

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Hose Clamps up to 25 mm Diameter3094
Engine/Transmission SupportT10012
Torque Wrench 5-50 NmV.A.G 1331
Torque Wrench 40-200 NmV.A.G 1332
Engine-Transmission JackV.A.G 1383 A
Step LadderVAS 5085
Hose Clip PliersVAS 6340
Drip Tray for VAS 6100VAS 6208
Transportation LockT10404

NOTE:

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.

Seal the disconnected fuel and ventilation lines to prevent dirt from getting into the system.

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

If engine oil must be drained because of work performed on the removed engine, it should be performed with the engine installed. If engine hangs on the holding fixture, engine is not in installation position and less engine oil flows out.

It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover plates of the brake discs are just above the floor. This enables the most ergonomic work position regarding accessibility of components in the engine compartment.

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 for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, 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.

Procedure

-- Check the DTC memory on all control modules Vehicle Diagnostic Tester.

NOTE:

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

CAUTION:

Danger of causing damage to other electronic components when disconnecting the battery.

Complete the steps for disconnecting the Battery.

-- Remove the battery and the battery tray. Refer to REMOVAL AND INSTALLATION .

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

Fig 1: Identifying Engine Control Module (E-Box) Cover

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-- Remove the air filter housing with the mass air flow sensor and connecting pipe AIR FILTER HOUSING .

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

Cabriolet

-- Remove the subframe crossbrace. Refer to SUBFRAME .

For all vehicles

-- Remove fan shroud. Refer to FAN SHROUD WITH COOLANT FAN .

-- Open the clamps -1- and -2- and remove the left lower air guide hose.

Fig 2: Identifying Clamps

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-- Open the clamps -1- and -2- and remove the right lower air guide hose.

Fig 3: Identifying Hose Clamps

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-- Loosen the hose clamp -2-.

Fig 4: Identifying Charge Air Pipe

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-- Remove the bolts -arrows-.

-- Disconnect the connector -1- from the charge air pressure sensor -G31- / intake air temperature sensor -G42- and remove the air guide pipe.

-- Seal the open lines and connections with clean plugs from the Engine Bung SetVAS 6122.

-- Remove the bolt -arrow- from engine coolant circulation pump 2 -V178-.

Fig 5: Identifying Engine Coolant Circulation Pump Bolt

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-- Remove engine coolant circulation pump 2 -V178-.

-- Remove the subframe. Refer to SUBFRAME .

-- Remove the EGR filter EXHAUST GAS RECIRCULATION OVERVIEW .

-- Loosen the bolts -1- and remove the heat shield from the right driveshaft.

Fig 6: Locating Heat Insulation Sleeve Bolts

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-- Remove the right driveshaft. Refer to DRIVE AXLE .

-- Remove the left driveshaft from the transmission. Refer to DRIVE AXLE .

-- Remove the vacuum hose -1- from the brake booster -2-.

Fig 7: Identifying Vacuum Hose

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-- Disconnect the connectors -1- through -3-.

Fig 8: Disconnect The Black

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-1- Exhaust Gas Temperature Sensor 2 -G448-
-2- Exhaust Gas Temperature Sensor 1G235
-3- Heated Oxygen Sensor -G39-

-- Remove the connector from the holder.

-- Disconnect the connector from Exhaust Gas Temperature 3 -G 495- -1- (attached behind the bracket).

Fig 9: Disconnect Connectors

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-- Guide the lines out of the brackets -2- on the plenum chamber bulkhead and turbocharger.

WARNING:

Very hot fuel can burn your skin.

The temperature of the fuel lines and may reach 100° C (212° F) after stopping the engine. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

-- Open the couplings -A- and -B- and remove the fuel lines. Open the couplings. Refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 10: Identifying Fuel Line Couplers

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-- Unclip the coolant hose bracket -1-.

Fig 11: Identifying Coolant Hose Bracket

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-- Free up the fuel lines.

-- Remove the fuel filter -7- from the mountings -1- through -3- and lay it on the engine.

Fig 12: Fuel Filter, Fuel Hoses And Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

See notes. Refer to FUEL FILTER, REMOVING AND INSTALLING .

-- Disconnect the connector -2-.

Fig 13: Disconnecting Connector -2- On Exhaust Pressure Sensor 1 -G450

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-- Remove the heat shield and disconnect the connector from Exhaust Pressure Sensor 2 -G451-. Refer to PARTICULATE FILTER OVERVIEW .

-- Disconnect the control line from Exhaust Pressure Sensor 2 -G451-.

-- Loosen the spring clamp. Use Spring Type Clip PliersVAS 6362.

-- Remove the bolts and bracket with the Exhaust Pressure Sensor 2 -G451- and lay them aside (the control wire to the particulate filter remains connected).

-- Remove the screw -3- and then remove the differential pressure sensor -G505- from the bracket -arrow-.

-- Remove the screw -1- at the top of the particulate filter mount.

-- Lay the Differential Pressure Sensor -G505- and mount on the particulate filter.

-- Seal the open lines and connections with clean plugs from the Engine Bung SetVAS 6122.

-- Remove the bolt -1-.

Fig 14: Identifying Windshield Wiper Fluid Reservoir Filler Tube -2- And Bolt

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-- Move the filler tube and windshield wiper fluid reservoir filler tube -2- to the side.

NOTE:

Ignore item -3-.

The installation location is shown with the fuel filter removed.

-- Disengage the fuel hose -2- from the bracket.

Fig 15: Disengaging Fuel Hose

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-- Removed the bracket for the fuel lines -arrow- and move it to the side.

-- Disconnect the connector -1- on the Auxiliary Fuel Pump -V393-.

-- Remove the screws -3- then remove the bracket and the Auxiliary Fuel Pump -V393- and move them to the side.

-- Remove the bolts -3- and the coolant reservoir -2-.

Fig 16: Identifying Coolant Reservoir, Bolts And Connector

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-- Unlock and disconnect the connector on the coolant reservoir.

-- Lay the coolant reservoir -2- on the engine.

-- Secure the decoupling element with Transportation LockT10404 -arrow-.

Fig 17: Identifying Decoupling Element

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-- Unlock the coolant hoses from the heater core -arrows- and then pull them off.

Fig 18: Identifying Heater Core Hoses

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-- Unlock and disconnect the connector -2- from the Wastegate Bypass Regulator Valve -N75- -1-.

Fig 19: Identifying Connector And Wastegate Bypass Regulator Valve

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-- Remove the nuts -arrows-.

-- Set the Wastegate Bypass Regulator Valve -N75- -1- with vacuum lines on the engine.

-- Disconnect the connectors -1-.

Fig 20: Connectors And Cable Guide

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-- Unclip the connector -1- and the locking mechanism -arrows- and open the cable guide -2-.

-- Remove the ground connection -3- and free up the wiring harness.

-- Disconnect and remove the connector -arrow-.

Fig 21: Identifying Bracket

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-- Remove the wiring harness from the bracket -1-.

-- Disconnect and remove the engine wiring connector from the engine control module, refer to ENGINE CONTROL MODULE .

-- Loosen the nuts -arrows- and disconnect the battery positive cables -1- from the E-box -2-.

Fig 22: Identifying Battery Cables

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-- Disconnect all other connectors between the starter, transmission and body.

-- Free up the wires.

Vehicles with A/C

-- Disconnect and remove the connector for the A/C compressor.

-- Disconnect the A/C compressor and tie it to the vehicle body. Refer to A/C COMPRESSOR .

CAUTION:

There is a risk of damaging the condenser, the A/C compressor and the refrigerant lines and hoses.

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

Vehicles with a DSG transmission

Fig 23: Mechatronic Unit Connector

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-- Remove the selector mechanism from the transmission. Refer to SELECTOR MECHANISM .

-- Turn and unlock the Mechatronic unit connector -arrow- and disconnect the connector.

Vehicles with a manual transmission

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

-- Remove the hose/line assembly or plastic hose from the clutch slave cylinder. Refer to CLUTCH HYDRAULIC HOSE/LINE OR PIPE .

-- Disconnect the connector from the Park/Neutral Position Switch -E17-.

For all vehicles

-- Remove the Engine Control Module -J623- from out of its mount. Refer to ENGINE CONTROL MODULE .

NOTE:

Loosen the bolts on the subframe mount two turns if the vehicle is still standing on the ground.

-- Disconnect the connector -arrow- from the oil level thermal sensor -G266-, if equipped.

Fig 24: Identifying Connector From Oil Level Thermal Sensor

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-- Loosen the fasteners -arrows- and remove the oil pan noise insulation -1-.

Fig 25: Identifying Oil Pan Noise Insulation

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-- Attach the engine bracketT10012 to cylinder block with bolt -1- and nut -2-. Tighten to approximately 20 Nm.

Fig 26: Attaching Engine/Trans. Support T10012 To Cylinder Block

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the Engine/Transmission SupportT10012 in Engine-Transmission JackV.A.G 1383 A.

-- Slightly lift the engine/transmission subassembly.

NOTE:

Use Step LadderVAS 5085 to be able to reach the subframe mount bolts.

Fig 27: Identifying Engine Mount Bracket Bolts

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-- Remove the engine mount bolts -arrows-.

-- Remove the bolts -arrows- for the transmission mount.

Fig 28: Identifying Bolts For Subframe Mount At Transmission

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CAUTION:

Risk of damaging hose and wiring connections as well as engine compartment.

Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
Carefully lower and guide the engine/transmission subassembly out of the engine compartment.
Make certain that there is enough clearance for the A/C compressor.

-- Lower the engine/transmission sub-assembly a little.

-- Move the engine/transmission subassembly forward and lower it a little more.