ENGINE AND TRANSMISSION MOUNT, ADJUSTING
Note. If the engine mount will only be adjusted, a bracket with spindle and hook 10-222 A/10 on the engine side is enough. It is not necessary to remove the air filter housing, battery and battery tray.
Special tools and workshop equipment required
- Engine Support Bridge 10-222 A
- Bracket with Spindle and Hook 10-222 A/10 (Qty: 2)
- Shackle 10-222 A/12
- Adapter 10-222 A/13 (GTI only)
- Torque Wrench (5-50 Nm) -V.A.G 1331
- Torque Wrench (40-200 Nm) -V.A.G 1332
- Bracket for Engine 10-222 A/1 (Eos only)
Procedure
Remove the engine cover. Refer to ENGINE COVER .
Remove the air filter housing. Refer to AIR FILTER HOUSING .
| CAUTION | Danger of causing damage to electrical components when disconnecting the battery. Complete the steps for disconnecting the battery. |
With the ignition turned off, disconnect the ground cable -arrow- from the battery.
Scheme 67
Remove the battery. Refer to Removal and Installation .
Remove the battery tray bolts -arrows- and tray.
Scheme 68
Install the engine support bridge 10-222 A using the following special tools
GTI
Scheme 69
- Adapter 10-222 A/13 (Qty: 2)
- Bracket with spindle and hook 10-222 A/10 (Qty: 2)
- Shackles 10-222 A/12 (Qty: 2)
Eos
Scheme 70
- Bracket for engine 10-222 A/1 (Qty: 2)
- Bracket with spindle and hook 10-222 A/10 (Qty: 2)
- Shackle 10-222 A/12
Note. Do not place the bracket for engine 10-222 A/1 on the fender panels. The panels will be damaged. The shackle 10-222 A/12 is needed to make sure the engine is lifted in its installed position and not tilted.
Continuation for all Vehicles
Support the engine and transmission but do not lift them.
Replace the engine mount to engine mount bracket bolts -arrows- one after the other, if this was not already performed when the engine was installed and tighten the bolts by hand.
Scheme 71
Vehicles with a Manual Transmission
Scheme 72
Replace the transmission mount to transmission mount bracket bolts -arrows- one after the other, if this was not already performed when the engine was installed and tighten the bolts by hand.
Vehicles with a Automatic Transmission
Scheme 73
Replace the transmission mount bracket to transmission mount bracket bolts -arrows- one after the other, if this was not already performed when the engine was installed and tighten the bolts by hand.
Continuation for all Vehicles
Loosen the engine and transmission mount bolts approximately 2 turns.
Adjust the engine and transmission mounts and tighten the bolts hand tight.
Scheme 74
- There must be a distance of at least 10 mm -a- between the engine mount bracket -2- and the right longitudinal member.
- The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1-.
Vehicles with a Manual Transmission
Scheme 75
- On the transmission side, the edges of the transmission mount support arm -1- and transmission mount -2- must be parallel.
- Dimension -x- is the same size on both sides of mount.
Vehicles with a Automatic Transmission
Scheme 76
- On the transmission side, the edges of the transmission mount support arm and transmission mount -B- must be parallel.
- Dimension -x- is the same size on both sides of bracket.
Continuation for all Vehicles
Tighten the engine and transmission mount bolts to specifications. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .
Further installation is performed in the reverse order.
ENGINE, REMOVING
Special tools and workshop equipment required
- Pry Lever-Rmv Outside Mirror -80-200
- Engine Sling -2024 A
- Engine-/Gearbox Jack -V.A.G 1383 A
- Hose Clip Pliers -V.A.G 1921
- Hose Clip Pliers -VAS 6362
- Step Ladder -VAS 5085
- Engine Bung Set -VAS 6122
- Drip Tray for -VAS 6100- -VAS 6208
- Engine Support -T10359
Note. To perform this procedure, the ground cable must be disconnected from the battery. If a coded radio is installed, obtain the anti-theft code beforehand. The engine is removed downward 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.
| CAUTION | When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route all lines and wires in their original locations. Ensure sufficient clearance to all moving or hot components. |
Check the Diagnostic Trouble Code (DTC) memories of all control modules. Refer to the vehicle diagnostic tester.
Disconnect the battery ground cable with the ignition turned off. Refer to Removal and Installation .
Remove the engine cover. Refer to ENGINE COVER .
Remove the air filter housing. Refer to AIR FILTER HOUSING .
Remove the battery, the battery tray bolts -arrows- and tray.
Remove the wiper arms. Refer to WIPER ARMS .
Remove the plenum chamber cover. Refer to one of the following
- GTI (2008 through 2009), Eos, and Passat. Refer to «Description and Operation»(ref-475581-S12372743572012052300000) .
GTI and Eos
Remove the plenum chamber bulkhead. Refer to Description and Operation .
Disconnect the engine wiring harness connector from the Engine Control Module (ECM). Refer to one of the following
- «Engine Control Module -J623-, GTI (2008 THROUGH 2009) AND EOS THROUGH 11.08»(ref-475527-S29783334492012052300000) .
- «Engine Control Module -J623-, GTI (FROM 2010) AND EOS FROM 12.08»(ref-475527-S42397903362012052300000) .
Continuation for all Vehicles
Scheme 77
Release the pass-through for the engine wiring harness -arrow- and pull off upward.
Remove the E-box cover by sliding both latches in the -direction of the arrows-.
Scheme 78
Remove the nuts and the cable for the generator -A- and the cable for the battery -B- from the fuse holder.
Scheme 79
Remove the bolt and the ground cable -arrow- from the longitudinal member.
Scheme 80
Open the wire guide locking mechanisms -arrows- on the longitudinal member.
Scheme 81
Free up the electrical connector -1- and disconnect it.
Scheme 82
Open the underlying wiring guide bracket -2-.
Remove the ECM wiring harness out of the wiring router and lay it on the engine.
Vehicles with a Manual Transmission
Remove the shift mechanism from the transmission. Refer to SHIFT MECHANISM .
Pinch off the hose from the master cylinder using the hose clamps up to 25 mm dia. -3094-.
Scheme 83
Pull out the clip -arrow- for the line up to the stop.
Scheme 84
Pull the line out of the breather/slave cylinder and seal it off.
| CAUTION | Do not press the clutch pedal. |
Vehicles with a Automatic Transmission
Remove the selector lever cable from the transmission. .
Vehicles with a Direct Shift Gearbox (DSG R)
Remove the selector lever cable from the transmission. Refer to SELECTOR LEVER CABLE, THROUGH 02.2009 or SELECTOR LEVER AND MECHANISM WITH CABLE, FROM 03.2009 .
Continuation for all Vehicles
Disconnect the connector -2-.
Scheme 85
Remove the upper bolts -upper arrows- from the fan shroud.
Scheme 86
Loosen the hose clamp -2-.
Scheme 87
Remove the bolt -4-.
Disconnect the electrical connector -arrow- and free up the electrical wire.
| WARNING | The coolant system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant. Reduce pressure by covering the coolant expansion tank cap with a cloth and open carefully. |
Open the coolant expansion tank cap.
Remove the noise insulation. Refer to Description and Operation .
Remove the front part of the wheel housing liner or the entire front wheel housing liner. Refer to Description and Operation .
Remove the charge air hoses -arrows-.
Scheme 88
Disconnect the electrical connector -1- and remove the lower bolts -lower arrows- for the fan shroud.
Remove the fan shroud downward.
Remove the bolt -1- and remove the charge air pipe downward.
Disconnect the electrical connector -2- for the engine coolant temperature sensor on radiator outlet -G83-.
Scheme 89
Note. Collect the leaking coolant in a clean container for disposal or reuse.
Place the drip tray for -VAS 6100- -VAS 6208- under the engine.
Drain the coolant. Refer to DRAINING AND FILLING .
Remove the coolant hoses -1 and 2-.
Scheme 90
| WARNING | The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Remove the hose connection carefully to release the pressure. |
Disconnect the lines from the fuel transfer.
Scheme 91
Vent line -1
Vacuum line -2
Fuel supply line -3
GTI, Eos, Passat and CC
Scheme 92
Remove the upper coolant hose -arrow- from the radiator.
Continuation for all Vehicles
Scheme 93
Disconnect the coolant hoses leading to the heater core -arrows-, to do this slightly pull the securing clip.
From above, remove the nuts -arrows- for the front exhaust pipe to the turbocharger.
Scheme 94
Disconnect the vacuum hoses -arrows-.
Scheme 95
Vehicles with Front Wheel Drive (FWD)
Scheme 96
Remove the right drive axle heat shield bolts -arrows- and shield.
Continuation for all Vehicles
Remove the drive axles. Refer to Removal and Installation .
| CAUTION | Risk of destroying due to a reversed running direction on a used ribbed belt. Before removing the ribbed belt, mark the running direction with chalk or a felt tip pen for reinstallation later. |
To release the tension on the ribbed belt, rotate the belt tensioner in the -direction of the arrow- from underneath.
Scheme 97
Secure the tensioner using the locking pin -T10060 A-.
Remove the ribbed belt.
Disconnect the connector -1- from the A/C compressor regulator valve -N280-.
Scheme 98
| WARNING | Refrigerant can cause serious personal injury. Do not open the Air Conditioning (A/C) refrigerant circuit. |
Remove the A/C compressor bolts -arrows-.
| CAUTION | Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend the refrigerant lines and hoses. |
Secure the compressor, with the refrigerant lines attached, to the longitudinal member.
GTI and Eos
Remove the generator -C-. Refer to Removal and Installation .
Continuation for all Vehicles
Scheme 99
Remove the after-run coolant pump bracket bolt -2-.
Note. The after-run coolant pump -V51- stays in the installed position.
First, remove the bolt -1- then the bolts -2 and 3- and then remove the pendulum support.
Scheme 100
Disconnect all remaining necessary electrical connectors from the engine and transmission and set them aside.
Disconnect all coolant, vacuum and intake hose connections from the engine.
Install the engine support -T10359- -1- to the engine and guide it into the mount.
Scheme 101
Set the support -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-. Tighten to approximately 20 Nm.
Scheme 102
Note. The threaded hole for the bolt -1- serves to secure the after-run coolant pump -V51-.
Install the engine-/gearbox jack -V.A.G 1383 A- to the engine support -T10359-.
Slightly lift the engine and transmission.
Note. Use the step ladder -VAS 5085- to remove the engine and transmission mount bolts.
Remove the engine mount to engine mount bracket bolts -arrows-.
Remove the transmission mount to transmission mount bracket bolts -arrows-.
Note. Verify that all hose and wire connections between the engine, transmission and body have been disconnected. To prevent damage, carefully guide the engine and transmission when lowering.
Vehicles with a DSG R
- Pay attention to the selector lever cable.
Continuation for all Vehicles
Pull the engine and transmission as far as possible to the left and slowly lower it.
Secure the engine to the engine and transmission holder -VAS 6095- when working on it. Refer to ENGINE, SECURING TO Engine and Transmission Holder VAS 6095 .
ENGINE, SECURING TO Engine and Transmission Holder VAS 6095
Special tools and workshop equipment required
- Engine Sling -2024 A
- Shop Crane - Load Cap = 700-1200KG -VAS 6100
- Engine and Transmission Holder -VAS 6095
Requirement
- The engine and transmission is removed and installed on the engine support -T10359-.
Separate the transmission from the engine. Refer to ENGINE AND TRANSMISSION, SEPARATING AND ASSEMBLING .
Install the engine sling -2024 A- as illustrated and lift the engine using the shop crane - load cap = 700-1200KG -VAS 6100- from the engine-/gearbox jack -V.A.G 1383 A-.
Scheme 103
| CAUTION | Use securing pins on the hooks and pins to prevent damaging the engine. |
Secure the engine to the engine and transmission holder -VAS 6095-.
ENGINE, INSTALLING
Installation is performed in the reverse order of removal, noting the following
| CAUTION | When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route all lines and wires in their original locations. Ensure sufficient clearance to all moving or hot components. |
Insert new alignment sleeves in the cylinder block for centering the engine and transmission.
Engage the intermediate plate at the sealing flange and slide it onto the alignment sleeves -arrows-.
Scheme 104
Vehicles with a Manual Transmission
Grease the input shaft splines lightly with grease for clutch plate splines -G 000 100-.
Inspect and install the clutch and clutch mechanism. Refer to [For transmission(s) 02Q] Removal and Installation .
Vehicles with a Direct Shift Gearbox (DSG R)
Replace the crankshaft needle bearings. Refer to CRANKSHAFT NEEDLE BEARINGS .
Install the selector lever cable. Adjust after installing. Refer to SELECTOR LEVER CABLE, THROUGH 02.2009 and SELECTOR LEVER AND MECHANISM WITH CABLE, FROM 03.2009 .
Continuation for all Vehicles
When installing the engine and transmission make sure there is enough clearance to the subframe and radiator. Adjust the engine and transmission mounts. Refer to one of the following
- GTI and Eos, refer to «ENGINE AND TRANSMISSION MOUNT, ADJUSTING»(ref-475556-S15307075032012052300000) .
Note. For the engine and transmission mount tightening specifications, refer to SPECIFICATIONS .
Electrical connections and routing. Refer to Wiring .
Connect the vehicle diagnostic tester.
Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries which may have occurred during the assembly.
Perform a test drive.
Then, perform the vehicle system test and repair any occurring malfunctions.
Note. If the DTC memory was erased, the readiness code must be generated again, refer to "Guided Fault Finding" in the vehicle diagnostic tester.
Tightening Specifications
| Bolted Connections | Tightening Specifications | |
|---|---|---|
| Bolts and Nuts | M6 | 10 Nm |
| M7 | 15 Nm | |
| M8 | 25 Nm | |
| M10 | 40 Nm | |
| M12 | 60 Nm |