Engine, Removing: Removing

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

-- Observe safety precautions. Refer to SAFETY PRECAUTIONS .

-- Follow repair instructions. Refer to GENERAL INFORMATION .

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 Engine and Transmission Holder - Engine Lateral Bracket T03001, engine is not in installation position and less engine oil flows out.

-- Check the Diagnostic Trouble Code (DTC) memory for all control modules Vehicle Diagnostic Tester.

-- Remove the air filter (engine cover). Refer to AIR FILTER HOUSING .

-- Remove the intake hose -4- between the Throttle Valve Control Module -J338- and air filter. To do this, disconnect air hose -1-, if present, and air hose -2- (compress securing ring) and remove spring clamp -3-.

Fig 1: Identifying Air Hoses And Are Fitted Securely

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All Vehicles

-- Remove the intake air scoop from the lock carrier -arrows-.

Fig 2: Identifying Air Guide On Lock Carrier

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

Fig 3: Identifying Engine Control Module (E-Box) Cover

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Vehicles with an Automatic Transmission

Fig 4: Identifying Bolts, Connector, Transmission Control Module And Bracket

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-- Unclip the transmission control module -3- from the bracket -7- and remove it upward.

-- Disconnect the connector -2- from the transmission control module.

All Vehicles

-- Remove the bolts -1 and 6-.

-- Move the bracket -7- with the power steering fluid reservoir to the side.

The hoses remain connected.

-- Disconnect the line -5- and free it up.

-- Disconnect the connector -4- from the Engine Control Module (ECM) and free up the engine wiring harness. Refer to ENGINE CONTROL MODULE .

Fig 5: Identifying Battery Housing Bolts

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

-- Disconnect the connector -4-, open the locking mechanism and lay the engine wiring harness -3- on the engine.

Fig 6: Identifying Harness Connector, Engine Wiring Harness, Ground (GND) Wire, Starter Connections & Multi-Function Switch Connector

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-- Disconnect the Ground (GND) cable -1- and the starter connections -2 and 5-.

Vehicles with an Automatic Transmission

-- Disconnect the connector -6- from the multifunction switch.

-- Remove the selector lever cable from the transmission. Refer to REMOVAL AND INSTALLATION .

Vehicles with a Manual Transmission

-- Remove the shift mechanism from the transmission. Refer to REMOVAL AND INSTALLATION .

-- Remove the brace -1-.

Fig 7: Clutch Slave Cylinder And Brace

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-- Remove the clutch slave cylinder -arrows- and move it to the side. Do not open the line system.

CAUTION: Do not operate the clutch pedal anymore after slave cylinder has been removed. Slave cylinder may be damaged by doing this.

-- Disconnect connector for back-up light switch from transmission.

All Vehicles

-- Disconnect vacuum hose from brake booster.

-- Disconnect the connector from the Heated Oxygen Sensor -G39- on the bulkhead. Move the wiring harness to the side.

-- Open the cap on the reservoir and then close it again to release the pressure in the coolant system.

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

NOTE: The vehicle has a manual hood support that is attached to the lock carrier.

-- Perform a service position. Refer to DESCRIPTION AND OPERATION .

-- Remove the radiator fan air shroud. Refer to COOLANT FAN .

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

-- Remove the ribbed belt. Refer to RIBBED BELT .

WARNING: Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

-- Remove the Air Conditioning (A/C) compressor from the auxiliary components bracket. Refer to REMOVAL AND INSTALLATION .

CAUTION: Risk of damaging refrigerant lines and hoses.

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

-- Secure the A/C compressor with the Tensioning Strap T10038 and a suitable mat onto the right longitudinal member.

-- Remove the clamps for the power steering pressure line on the transmission. Refer to DESCRIPTION AND OPERATION .

Fig 8: Expansion Hose Routing On Automatic Transmission

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-- Remove the nuts -1- and the power steering pump line.

Fig 9: Identifying Nuts For Power Steering Pump Hose

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-- If the vehicle has an engine pre-heater, remove the cable -2-.

-- Remove the power steering pump from the auxiliary components bracket and move it forward. Refer to REMOVAL AND INSTALLATION .

The power steering lines remain connected to the power steering pump.

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

Fig 10: Identifying Nuts, Bolts & Front Exhaust Pipe

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-- Remove the front exhaust pipe -1- from the exhaust manifold and tie it to the side. Refer to CATALYTIC CONVERTER .

CAUTION:

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 right drive axle. Refer to REMOVAL AND INSTALLATION .

-- Remove the left drive axle from the transmission. Refer to REMOVAL AND INSTALLATION .

-- Disconnect the fuel supply line -1- and the bleeder line -2-. Refer to Removal And Installation .

Fig 11: Identifying Supply Line (Metal Coupling)

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-- Seal the lines so that the fuel system is not contaminated by dirt etc.

-- Remove the coolant hoses from the heat exchanger -arrows-.

Fig 12: Identifying Heater Core Hoses

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-- Open the spring clamps -arrows- and remove the coolant hoses from the radiator.

Fig 13: Identifying Spring Clamps And Radiator Coolant Hoses

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-- Remove the bolt -2- and move the windshield washer filler tube forward -1-.

Fig 14: Identifying Bolt, Windshield Washer Reservoir & Connectors

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-- Remove the connector -3-.

-- Remove the bolts -5- and place the coolant expansion tank -4- on top of the engine with the hoses connected.

NOTE: Loosen the bolts on the engine mount and transmission mount one turn.

-- Attach the Engine Holder Bracket T03000 as follows:

Fig 15: Identifying Engine Holder Bracket T03000

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Remove the Pin T03000/1 from the Engine Holder Bracket T03000.
Attach Engine Holder Bracket T03000 to the cylinder block with pin -3- and tighten bolts -1 and 2- hand-tight.
Then screw in Pin T03000/1 and tighten to 20 Nm.
Then tighten bolts -1 and 2- to 25 Nm.

-- Place Engine/Gearbox Jack V.A.G 1383 A on Engine Holder Bracket T03000 and raise engine/transmission subassembly slightly.

WARNING: Use a Step Ladder VAS 5085 when removing the bolts from the engine/transmission mount.

-- Remove engine mount from above. To do this, remove the bolts -1, 2 and 3-.

Fig 16: Identifying Engine Mount Bolts

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NOTE: The rear bolt -2- is accessible through a hole in the wheel housing.

-- Remove the transmission mount from he transmission holder -arrows-.

Fig 17: Identifying Transmission Side Of Assembly Mounting At Top Of Transmission Carrier

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NOTE:

Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.

A 2nd technician is needed to lower the engine/transmission subassembly.

The engine/transmission subassembly must be guided with care to prevent damage while lowering.

-- Carefully lower the engine/transmission subassembly. When doing this, rotate or push the engine/transmission subassembly.