Engine, Removing

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

Special tools and workshop equipment required

Tensioning Strap T10038
Locking Pin T10060 A
Engine Support T10359 with Pin T10359/2
Torque Wrench (5-50 Nm) V.A.G 1331
Torque Wrench (40-200 Nm) V.A.G 1332
Engine-/Gearbox Jack V.A.G 1383 A
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Drip Tray for VAS 6100 VAS 6208
Hose Clip Pliers VAS 6362
Sealing Tool T10249
Guide Pins T10093
Adapters for Service Position T10467
Cable Tie

NOTE:

The engine is removed downward together with the transmission.

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

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

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

If the engine oil must be drained because of work performed on the removed engine, it should be drained when the engine is still installed. If the engine hangs on the engine lateral bracket T03001, the engine is not in its installed position and less engine oil will drain out.

It is advisable to remove the front wheels before removing the engine and transmission assembly. The vehicle can be lowered on the hoist until the brake cover plates 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, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and 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.

-- Check the Diagnostic Trouble Code (DTC) memory of all control modules. Refer to the vehicle diagnostic tester.

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

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

-- Remove the connecting pipe from the Mass Airflow (MAF) sensor.

Fig 1: Identifying Charge Air Pipe Bolt And Hose Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Press the release buttons, remove the intake hose -1- and move it to the side.

-- Remove the charge air pipe bolt -arrow-.

-- Remove the charge guide pipe, to do this, loosen the hose clamp -2-.

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

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

Fig 2: Identifying Engine Control Module (E-Box) Cover

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-- Remove the nut and wire -2-.

Fig 3: Identifying ECM Connector

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-- Disconnect the connector -1- from the Engine Control Module (ECM) and free up the engine wiring harness. Refer to Engine Control Module -J623- .

-- Move the lock carrier into the service position. Refer to DESCRIPTION AND OPERATION .

with a Manual Transmission

-- Remove the shift mechanism from the transmission. Refer to [For transmission(s) 0A4] Removal and Installation [For transmission(s) 02Q] Removal and Installation [For transmission(s) 02E] Removal and Installation .

-- Remove the clutch master cylinder supply hose -2- from the brake fluid reservoir -4-.

Fig 4: Identifying Supply Hose

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-- Seal the supply hose -2- using the sealing tool T10249 -1- or a plug from the engine bung set VAS 6122.

-- Secure the supply hose -2- out of the way.

-- Pull out the clip -arrow- for the hose/line assembly -A- to the stop.

Fig 5: Hose/Line Assembly/Pipe & Breather Assembly/Slave Cylinder Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the hose/line assembly -A- out of the breather assembly and seal it off.

CAUTION: Do not operate the clutch pedal any more.

with a Direct Shift Gearbox (DSG®)

-- Remove the selector lever cable from the transmission. Refer to [For transmission(s) 02E] Specifications ,[For transmission(s) 09G] Removal and Installation .

Continuation for All

-- Remove the nut and ground wire -arrow- from the longitudinal member.

Fig 6: Ground (GND) Cable On Longitudinal Member

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-- Disconnect the connector -2-.

Fig 7: Ground (GND) Cable, Electrical Connector, Cable Tie & Protective Boot

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-- Remove the fan shroud upper bolts -arrows-.

Fig 8: Coolant Fan Control (FC) Control Module J293

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the hose clamp -2-.

Fig 9: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -4-.

-- Disconnect the connector -arrow- and free up the wire.

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

The coolant system is under pressure when the engine is warm.
Wear protective goggles and protective clothing to prevent damage to eyes and scalding.
Reduce pressure by covering the coolant expansion tank cap with a cloth and carefully opening.

-- Open the coolant expansion tank cap.

-- Loosen the drive axle bolts. Refer to DESCRIPTION AND OPERATION .

-- Remove both front wheels.

-- Remove the noise insulation. Refer to REMOVAL AND INSTALLATION .

-- Remove the front wheel housing liners. Refer to REMOVAL AND INSTALLATION .

-- Remove the charge air hoses -arrows-.

Fig 10: Disconnecting Charge Air Hoses

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-- Remove the bolt -1- and remove the charge air pipe downward.

Fig 11: Air Guide Hose Bolts, Air Guide Pipe Hose Clamps & Electrical Harness Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -1- and remove the fan shroud lower bolts -arrows-.

Fig 12: Coolant Fan Control (FC) Control Module J293

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the fan shroud downward.

-- Disconnect the connector -2- from the engine coolant temperature sensor on radiator outlet.

Fig 13: ECT Electrical Connector

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NOTE: Store drained coolant in a clean container for disposal or to be reused again later.

-- Place the drip tray for VAS 6100 VAS 6208 under the engine.

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

-- Disconnect the coolant hoses -1 and 2-.

Fig 14: Coolant Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING: The fuel system is under pressure!

Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin.
Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

-- Disconnect the fuel supply line -1- and the vent line -2-. Refer to "Coupling, Disconnecting" in Description And Operation .

Fig 15: Identifying Supply Line (Metal Coupling)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the upper coolant hose -arrow- from the radiator.

Fig 16: Identifying Radiator Upper Coolant

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-- Remove the coolant hoses -arrows- from the heater core.

Fig 17: Disconnecting Coolant Hoses To Heater Core At Bulkhead

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-- Remove the right drive axle heat shield bolts -arrows- and shield.

Fig 18: Drive Axle Heat Shield Bolts

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-- Remove the drive axles. Refer to REMOVAL AND INSTALLATION .

-- From the top, remove the front exhaust pipe to exhaust manifold/turbocharger nuts -arrows-

Fig 19: Front Exhaust Pipe/Turbocharger Nuts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

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

-- Disconnect the solenoid clutch electrical connector -1- from the Air Conditioning (A/C) compressor.

Fig 20: A/C Compressor Bolts And Solenoid Clutch Electrical Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

WARNING: Risk of injury from refrigerant:

Do not open the A/C refrigerant circuit.

-- Remove the A/C compressor bolts -arrows-.

CAUTION: Danger of causing damage to the refrigerant lines:

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

-- Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.

-- Remove the after run coolant pump bracket bolt -2-.

Fig 21: After-Run Coolant Pump V51 Bracket Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE: The after run coolant pump stays in the installed position.

-- Remove the pendulum support bolt -1-.

Fig 22: Identifying Pendulum Support & Bolts

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-- Then, remove the pendulum support bolts -2 and 3- and remove the pendulum support.

Fig 23: Identifying Vacuum Hoses

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-- Disconnect the vacuum hoses -arrows-.

-- Disconnect all remaining electrical wires from the engine and transmission, as necessary and set them aside.

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

Install the pin T10359/2 to the engine support T10359 and mount the tensioner from the transmission set.

-- Install the engine support T10359 -1- to the engine and guide it onto the mount.

Fig 24: Identifying Engine Support With Additional Supports

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-- Seat the tensioner -3- in order to prevent the engine from tilting out of the engine support T10359.

-- Secure the engine support T10359 -1- to the cylinder block using the bolt -3- and tighten it to approximately 20 Nm.

Fig 25: Identifying Engine Support And Threaded Hole Location

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NOTE: The threaded hole for the bolt -3- serves to secure the after run coolant pump.

-- Install the engine-/gearbox jack V.A.G 1383 A to the engine support T10359.

-- Slightly tension the engine and transmission subassembly.

NOTE: Use the step ladder VAS 5085 to remove the engine and transmission mount to bracket bolts.

-- Remove the engine mount to engine mount bracket bolts -arrows-.

Fig 26: Identifying Engine Mount Bolts

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with a Manual Transmission

Fig 27: Identifying Bolts For Subframe Mount At Transmission

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-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

with a DSG®

Fig 28: Identifying Engine Mount To Engine Mount Bracket Bolts

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-- Remove the transmission mount to transmission mount bracket bolts -arrows-.

Continuation for All

NOTE:

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

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

with a DSG®

-- Pay attention to the selector lever cable.

Continuation for All

-- Pull the engine and transmission as far as possible to the left front and slowly lower it.

Secure the engine to the engine and transmission holder VAS 6095 whenever working on it. Refer to ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095 .