Engine, Removing: Procedure

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 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.

Fig 1: Identifying Coolant Reservoir Cap

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WARNING: Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.

-- Remove the cap -arrow- from the coolant reservoir.

-- Remove the engine cover, refer to ENGINE COVER .

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

-- Remove the air filter housing, refer to AIR FILTER HOUSING .

-- Remove the battery tray, refer to [For transmission(s) 0A4, 02E, 09G, 02Q] Battery, Starter, Generator, Cruise Control .

-- Remove the radiator, refer to RADIATOR .

-- To prevent damage, cover the charge air cooler using suitable workshop equipment.

-- Loosen the hose clamps -1- and -3-.

Fig 2: Identifying Lower Air Guide Pipe

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-- Disconnect the connector from the Charge Air Pressure Sensor - G31- -arrow-.

-- Remove the bolts -2- and -4- and remove the lower air guide pipe -5-.

-- Remove the vacuum hose -3- from the connector -arrow- and remove the vacuum line -2-.

Fig 3: Identifying Vacuum Pump

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-- Press the vacuum hose release buttons -2- and remove from the vacuum pump -1-.

-- Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger.

Fig 4: Identifying Heater Core Hoses

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NOTE: There may be a heat shield installed, which dose not need to be removed.

-- Hold the coolant hoses downward and drain the coolant.

-- Remove the front left and right wheel housing liners. .

Vehicles with secondary air injection system

-- Open the release -arrows- and remove the lines -1- from the Secondary Air Injection Pump Motor -V101- -2-.

Fig 5: Locating Release

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Continuation for all vehicles

-- Remove the catalytic converter, refer to CATALYTIC CONVERTER WITH FRONT EXHAUST PIPE .

-- Disconnect the hose couplings -1- and -2- as shown in the above graphic. . Loosen the hose clamp from the expansion tank -3-.

Fig 6: Identifying Expansion Tank

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

Fig 7: Identifying Battery Cables

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Vehicles with secondary air injection system

-- Squeeze the locking ring on both side and remove the connecting pipe -1-.

Fig 8: Identifying Connecting Pipe And Connector

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-- Carefully unclip the secondary air system bracket -4-.

Fig 9: Identifying Brackets And Clips

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-- Unclip clip -3- and remove both secondary air lines.

Continuation for all vehicles

-- Remove the ground connection -2- and free up the cable guide -1-.

-- Release and disconnect the connectors -3-.

Fig 10: Locating Connectors

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-- Open the cable guide -1- locking devices -arrows- and lay the wiring harness on the engine.

-- Disconnect and remove the connector -arrow-.

Fig 11: Identifying Bracket

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

-- Remove the selector lever cable from the transmission.

Fig 12: Identifying Selector Lever Cable

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-- Remove the bolts -arrows- and set the selector lever cable -2- with cable bracket -1- aside.

NOTE: Do not bend or kink the selector lever cable.

EVAP canister in the engine compartment

Fig 13: Locating Tab

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-- Remove the vent line -arrow-, refer to the above graphic. .

-- Release the tab -3- in the direction of the -arrow- and remove the EVAP canister -1- upward.

-- Lay the EVAP canister -1- on the engine with the line attached -2-.

Continuation for all vehicles

Fig 14: Identifying Coolant Expansion Tank And Windshield Washer Fluid Reservoir Filler Tube

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-- Remove the bolt -4- and rotate the windshield washer fluid reservoir filler tube -2- forward.

-- Open the clip -3- and remove the connector -5- from the coolant expansion tank -1-.

-- Remove the bolts -arrows- and place the coolant expansion tank -1- on top of the engine with the hoses connected.

-- Loosen the bolt -1- for the engine mount -2- approximately two turns.

Fig 15: Identifying Engine Mount Bolts

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-- Remove the bolts -2- on the transmission mount -1- two turns.

Fig 16: Identifying Transmission Mount Bolts

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-- Pivot the tensioner in direction of -arrow- to relieve tension on ribbed belt.

Fig 17: Rotating Tensioner

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-- Secure the tensioning system using Locking Pin T10060A.

CAUTION: Risk of damage due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioning device.

-- Disconnect the connector -1- on the A/C Compressor Regulator Valve -N280-.

Fig 18: Identifying A/C Compressor Components

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-- Remove the bolts -arrows-.

WARNING: Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

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.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached.

-- Remove the left and right drive axle, refer to Drive Axle Overview .

Vehicles with coolant auxiliary cooler

Fig 19: Identifying Auxiliary Cooler And Bracket

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-- Remove the nuts -arrows- from the coolant auxiliary cooler bracket -2-.

-- Unclip the air guide on the coolant auxiliary cooler.

-- Remove the coolant auxiliary cooler -1- with the bracket -2- and attached coolant hoses and secure to engine.

Continuation for all vehicles

Fig 20: Identifying After-Run Coolant Pump

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-- Remove the connector -arrow- from the After-Run Coolant Pump -V51- -1-.

-- Remove the nut -3- and remove the After-Run Coolant Pump -V51- -1- from the bracket -2-.

-- Operate the release -arrow- and remove the coolant hose -1- from the controller housing.

Fig 21: Identifying Coolant Hose Release

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-- Remove the bolts -arrows- and move the bracket to the side.

Fig 22: Identifying Bracket

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-- Remove the bolt -arrow- for the bracket -1-.

Fig 23: Identifying Bracket Bolt

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-- Lightly push the wires -2- upward.

-- Position the Engine/Gearbox Jack - Adapter T10359/3 on the Engine/Gearbox Jack - Engine Support T10359 from above and secure it.

Fig 24: Identifying Engine/Gearbox Jack Engine Support

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-- Tighten Engine/Gearbox Jack - Pin T10359/2 with support element -A- from the Transmission Support 3282 to the engine bracket.

-- Position the Engine/Gearbox Jack - Engine Support T10359 on the Engine/Gearbox Jack VAG1383A and bring it into position with the engine/transmission assembly.

-- After the Engine/Gearbox Jack - Engine Support T10359 is positioned correctly, install the bolt -A- with the spacer sleeve on the Engine/Gearbox Jack - Engine Support T10359.

Fig 25: Identifying Engine Support

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-- Secure the engine bracket on engine using the securing element -B- from the Transmission Support 3282 and slightly lift the engine/transmission subassembly.

CAUTION: Make sure that no components/hoses are damaged, over-stretched or torn when lifting or lowering engine using Engine Support Bridge 10-222A.

-- Carefully remove the bolts -1- for the engine mount -2-.

Fig 26: Identifying Engine Mount Bolts

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-- Remove the bolts -2- completely.

Fig 27: Identifying Transmission Mount Bolts

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NOTE: Depending on the transmission there can be two or three bolts.

CAUTION: Danger of causing damage to the vacuum lines or electric wires as well as to the engine compartment.

Make sure all the vacuum lines or electric wires between the engine, the transmission and the body are loosened.
Carefully lower and guide the engine/transmission subassembly out of the engine compartment.

-- Carefully lower the engine/transmission sub-assembly in direction of -arrow 1-.

Fig 28: Identifying Engine Jack

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-- Carefully guide the engine/transmission sub-assembly forward and out to the left in direction of -arrow 2-.