3.2L - Engine Assembly - Engine Code(s): Bub & Cbra: Other Volkswagen Eos I

ENGINE, REMOVING

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine Support T40074
3. Torque Wrench (5-50 Nm) V.A.G 1331
4. Torque Wrench (40-200 Nm) V.A.G 1332
5. Engine-/Gearbox Jack V.A.G 1383 A
6. Step Ladder VAS 5085
7. Spring Type Clip Pliers VAS 5024 A
8. Engine and transmission holder VAS 6095
9. Shop Crane - Load Cap = 700-1200 KG VAS 6100
10. Drip Tray for VAS 6100 VAS 6208
11. Engine Support 3269
12. Container for Removed Parts V.A.G 1698
13. Engine Bung Set VAS 6122
14. Cable Ties
15. High Temperature Grease G 052 133 A2

The engine with transmission is removed downward.

Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal. Refer to "Guided Fault Finding" in the vehicle diagnostic tester.

Note. All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine. Leave the key in the ignition lock to prevent the steering lock from engaging. 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 cover plates for the brakes are just above the floor. This enables the most ergonomic work position possible regarding accessibility of components in the engine compartment. When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing the engine. To prevent damage to the removed components, use the container for removed parts V.A.G 1698 for storage.

Disconnect the battery ground cable with the ignition turned off. Refer to REMOVAL AND INSTALLATION .

Completely remove the air filter housing with connecting pipe to the throttle valve control module -J338-. Refer to AIR FILTER HOUSING OVERVIEW .

Remove the air filter housing bracket.

Remove the windshield wiper arms, plenum chamber cover and plenum chamber facing wall. Refer to WIPER ARMS , PLENUM CHAMBER COVER . .

Vehicles with a Engine Control Module (ECM) equipped with a Anti-Theft Immobilizer

Remove the protective housing from the ECM. Refer to ENGINE CONTROL MODULE, WITH A ANTI-THEFT IMMOBILIZER .

Continuation for all Vehicles

Disconnect the engine harness connector from the ECM.

Release the pass-through for the engine harness -arrow- and pull off upward.

Scheme 398

Remove the nut and generator wire -arrow- from the fuse holder.

Scheme 399

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

Scheme 400

Open the cable guide locking mechanisms -arrows- on the longitudinal member.

Scheme 401

Disconnect all engine/body harness connectors and set the engine harness on the engine.

Pay attention to the rules of cleanliness. Refer to CLEAN WORKING CONDITIONS .

Disconnect the fuel supply line -1- (black) and catch any leaking fuel with a cloth.

Scheme 402

Disconnect the ventilation line -2- (white) and remove the EVAP canister.

Note. Press the locking ring to release the lines. The vacuum line (green) for the leak detection pump -V144- must also be disconnected.

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

Disconnect the connectors from the Heated Oxygen Sensors (HO2S) on the plenum chamber bulkhead and free up the wires.

Scheme 403

1 - Heated oxygen sensor 2 -G108-, 6 pin connector (brown)

2 - Heated oxygen sensor -G39-, 6 pin connector (black)

Disconnect all electrical wires from the engine/transmission and set aside.

Disconnect the brake booster vacuum hose from the intake manifold.

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

Disconnect the selector mechanism from the transmission. Refer to SELECTOR LEVER CABLE, THROUGH 02.2009 , or SELECTOR LEVER AND MECHANISM WITH CABLE, FROM 03.2009 .

Open and close the cap on the expansion tank, to relieve the cooling system pressure.

Remove the noise insulation. Refer to REMOVAL AND INSTALLATION .

Remove the front sections of the wheelhouse liners. Refer to REMOVAL AND INSTALLATION .

Scheme 404

Bring the lock carrier into the service position. Refer to "Lock Carrier" in DESCRIPTION AND OPERATION .

Remove the noise insulation right support from the lock carrier.

Disconnect the connector from the oil level thermal sensor -G266-.

Disconnect the wire bracket from oil level thermal sensor at subframe.

Remove the front exhaust pipe with catalytic converters. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS .

Note. Do not bend the coupling elements in the exhaust pipe more than 20° or they could be damaged. A second mechanic is required for the removal.

Note. To prevent damage to the Air Conditioning A/C condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

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

Remove the ribbed belt. Refer to RIBBED BELT .

Open refrigerant line retainers on the body.

Remove the A/C compressor, with the refrigerant lines still connected, from the accessory bracket REMOVAL AND INSTALLATION .

Secure the A/C compressor -A- to the lock carrier as shown (fasteners -1 and 2-).

Scheme 405

Remove the right drive axle heat shield.

Remove the drive axles. Refer to REMOVAL AND INSTALLATION .

Remove the bolts -1 through 3- and remove the pendulum support.

Scheme 406

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect the coolant hose quick release couplings at the radiator and heater core.

Remove the coolant hoses from the expansion tank.

Install the engine support T40074 to the engine-/gearbox jack V.A.G 1383 A.

Remove a adapter T40074/1 from the engine support T40074 and secure it to the cylinder block with a nut -1-.

Scheme 407

Position the engine support T40074 to the engine as illustrated and install the adapter T40074/1 to the engine support T40074 with the bolt -2-.

Scheme 408

Secure the engine support T40074 to the exhaust side of the cylinder block with two M10 X 25 bolts -arrows- as illustrated and tighten them to approximately 20 Nm.

Scheme 409

Gently lift the engine and transmission using the engine-/gearbox jack V.A.G 1383 A.

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

Scheme 410

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

Scheme 411

Note. Use the step ladder VAS 5085 to remove the bolts. Carefully guide the engine and transmission, when lowering, to prevent damage to the body.

Carefully lower the engine with transmission.

ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine and Transmission Holder VAS 6095
3. Engine-/Gearbox Jack V.A.G 1383 A
4. Shop Crane - Load Cap = 700-1200 KG VAS 6100
5. Engine Support 3269

Secure the engine to the engine and transmission holder VAS 6095 when working on it.

Procedure

Remove the transmission.

Install the lifting tackle 3033 as shown and lift the engine off of the engine-/gearbox jack V.A.G 1383 A using the shop crane - Load Cap = 700-1200 KG VAS 6100.

Scheme 412

Vibration damper side: Position 3.

Flywheel side: Position 11.

Using the engine and transmission holder VAS 6095 with the universal mounts

Scheme 413

Secure the engine to the engine and transmission holder VAS 6095 as shown.

Using the engine support 3269

Scheme 414

Secure the engine support 3269 to the cylinder block as shown.

ENGINE, INSTALLING

Installation is carried out in the reverse order while noting the following

A pilot needle bearing must be installed in the crankshaft. Install the needle bearing, if necessary. Refer to CRANKSHAFT NEEDLE BEARING .

Lubricate a used needle bearing lightly with high temperature grease G 052 133 A2.

Make sure the alignment sleeves for centering the engine and transmission are installed in the cylinder block. Install them if necessary.

When installing the engine and transmission assembly, check for clearance to the subframe as well as to the radiator.

Align the engine mount as follows

Scheme 415

1. There must be a distance of at least 10 mm -a- present between the engine mount bracket and right longitudinal member.
2. The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1-.

Install the pendulum support and bolts. see scheme 3

Note. For the engine and transmission mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .

Install the drive axles. Refer to REMOVAL AND INSTALLATION .

Install the front exhaust pipe with catalytic converters. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS .

Note. Ensure the exhaust system is installed free of tension. Refer to EXHAUST SYSTEM, INSTALLING .

If necessary, adjust the selector lever cable. Refer to SELECTOR LEVER CABLE, ADJUSTING .

Install the Air Conditioning (A/C) compressor. Refer to REMOVAL AND INSTALLATION .

Install the ribbed belt. Refer to RIBBED BELT .

Reset the lock carrier. Refer to "Lock Carrier" in DESCRIPTION AND OPERATION .

Note. Before installing the front bumper cover, ensure the noise insulation can be installed free of tension. If necessary, loosen the noise insulation right bracket from the lock carrier.

Install the noise insulation. Refer to REMOVAL AND INSTALLATION .

Fill the coolant. Refer to DRAINING AND FILLING .

Perform a vehicle system test. Refer to "Guided Fault Finding" in the vehicle diagnostic tester.

End the vehicle system test, this will automatically erase any Diagnostic Trouble Code (DTC) entries which occurred during the reassembly.

Generate a readiness code in conjunction with a road test.

Observe the safety precautions that apply to road tests.

Perform a test drive.

Then, perform a vehicle system test again and repair any occurring malfunctions if necessary.

Tightening Specifications

Note. For the engine and transmission mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .