Engine, Supporting In Installed Position

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

Engine Support Bridge10 - 222 A
Spindle10 - 222 A /11
Shackle10-222 A/12
Holder10 - 222 A /7
Support Bracket10 - 222 A /28
Support Bracket10 - 222 A /31
Rail with HolesT40091/2 from Engine Support Basic SetT40091
MountT40093/5 from Engine Support Supplement SetT40093A
2 x Engine Support Adapter10 - 222 A /28-1
2 x Square PipeT40091/1 from Engine Support Supplement SetT40093A.
2 x Square PipeT40091/1 from Engine Support Supplement SetT40093A.
2 x Movable JointT40093/4 from Engine Support Supplement SetT40093A.
Torque Wrench 5-50 NmV.A.G 1331

Procedure

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.

CAUTION:

Danger of causing damage to the decoupling element

Do not bend the decoupling element more than 10°.
Do not stretch the decoupling element.
Do not damage the wire mesh on the decoupling element.

-- Remove the exhaust system bracket from the subframe -arrows- to prevent damaging the decoupling element.

Fig 1: Identifying Exhaust System Bracket (Suspended Mount) Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the noise insulation. Refer to NOISE INSULATION OVERVIEW .

-- Remove the bolt -1-.

Fig 2: Identifying Pendulum Support

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

-- Remove the pendulum support.

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

-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER .

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

-- Remove the lock carrier trim. Refer to LOCK CARRIER .

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 .

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 3: Identifying Fuel Line Couplers

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-- Unclip the coolant hose bracket -1-.

Fig 4: 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 5: Fuel Filter, Fuel Hoses And Bolts

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NOTE:

See notes. Refer to OVERVIEW - FUEL FILTER .

-- Disconnect the connector -2-.

Fig 6: Disconnecting Connector -2- On Exhaust Pressure Sensor 1 -G450

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-- 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 7: 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 8: 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 9: Identifying Coolant Reservoir, Bolts And Connector

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-- Disconnect and remove the connector for the coolant reservoir -2-.

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

-- Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Fig 10: Identifying Release Buttons

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-- Disconnect the connector from the crankcase ventilation hose -1-.

-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Remove bolt -2- and tilt the air guide pipe with the intake hose backward and remove from the turbocharger.

-- Remove the bolts -arrows- from the left and right sides of the lock carrier bracket.

Fig 11: Identifying Bolts

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-- Remove the lower mount on the Adapter10 - 222 A /28 and replace it with the engine support adapter 10-222 A /28-1.

Fig 12: Identifying Engine Support Bridge - Engine Support And Bolts

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-- Remove the bolts -arrows- on the engine support bridge mounting from the engine support adapter 10-222 A /28-1.

-- Use the bolts from the engine support adapter 10-222 A /28-1 for attaching the Adapter10 - 222 A /28. Do not use the bolts for the bracket.

Fig 13: Identifying Engine Support Adapter

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-- Bolt tightening specification -arrows- 8 Nm

CAUTION:

A second technician is needed to mount the Engine Support Bridge10 - 222 A on the vehicle to prevent the Engine Support Bridge from tipping.

Assemble engine support bracket as illustrated.

Install the Adapter10 - 222 A /31-1 on the suspension strut tower.

Fig 14: Identifying Engine Support Bridge

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Adapter10 - 222 A /31-2
Moveable JointT40091/3
Support Bracket 10 - 222 A /31-1
Rail with HolesT40091/2
Moveable JointT40093/4
Square PipeT40091/1
Adapter10 - 222 A /28 with engine support adapter 10-222 A /28-1
MountT40093/5
Spindle10 - 222 A /11
Bracket With Spindle and Hook10 - 222 A /10

-- Tighten all threaded connections on the Engine Support Bridge hand-tight. Adjust the height of the Engine Support Bridge parallel over the Adapter10 - 222 A /28.

-- Pretension the engine/transmission sub-assembly using the spindles, but do not lift it.