2.0L - Engine Assembly - Engine Code(s): Cjaa: Other Volkswagen Golf Mk6

ENGINE AND TRANSMISSION MOUNT, ADJUSTING

Special tools and workshop equipment required

1. Engine Support Bridge 10-222 A
2. Engine Support Adapter 10-222 A/3
3. Adapter 10-222 A/18
4. Bracket for Engine 10-222 A/1
5. Torque Wrench (5-50 Nm) V.A.G 1331
6. Hose Clip Pliers VAS 6362

Procedure

Remove the engine cover. Refer to ENGINE COVER .

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

Remove the intake tube between the mass airflow sensor -G70- and the adapter on the turbocharger.

Turn off the ignition and disconnect the ground cable -arrow- from the battery. Refer to Removal and Installation .

Scheme 298

Remove the battery, the battery tray bolts -arrows- and tray.

Scheme 299

Remove the auxiliary fuel pump -V393- or fuel pump 2 -V277-. The fuel lines remain connected. Refer to Auxiliary Fuel Pump -V393- OR Fuel Pump 2 -V277 .

Install the engine support bridge 10-222 A with the necessary adapters as illustrated and support the engine in the installed position.

Scheme 300

Note. The subframe bolts may only be loosened when the engine is supported using the engine support bridge 10-222 A.

Replace the engine mount to engine mount bracket bolts -arrows- one after the other (if not already done) and tighten them by hand.

Scheme 301

Replace the transmission mount to transmission mount bracket bolts -arrows- one after the other (if not already done) and tighten them by hand.

Scheme 302

Loosen the engine mount to engine mount bracket bolts and the transmission mount to transmission mount bracket bolts approximately 2 turns.

Scheme 303

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

Scheme 304

The edges of the transmission mount support arm -1- and the transmission mount -2- are parallel.

1. Dimension -x- is the same dimension on both sides of bracket.

Tighten the engine and transmission mount bolts.

1. For the correct tightening specifications, refer to «FASTENER TIGHTENING SPECIFICATIONS»(ref-481028-S10935909172012061900000) .

Further installation is in the reverse order of removal. When doing this note the following

1. Make sure the fuel lines are securely fastened.
2. Do not interchange the supply and return lines (the return line is blue or has a blue mark, the supply line is black).

Observe the notes after connecting the battery. Refer to Removal and Installation .

ENGINE COVER

Removing

Pull the engine cover out of the mounts in these areas -arrows- and in the sequence shown. Reach as far as possible under the engine cover.

Scheme 305

Installing

Press the ball sockets on the engine cover into the correct position, if necessary.

Scheme 306

Position the engine cover on the ball studs and press down on the cover in the corners until secure.

ENGINE, REMOVING

Special tools and workshop equipment required

1. Shop Crane - Load Cap = 700-122 KG VAS 6100
2. Lifting Tackle 3033
3. Wrench SW 13T10384

Note. Be sure to obtain the radio anti-theft code because it will be necessary to disconnect the battery ground cable later in the procedure. The engine is removed forward 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.

Disconnect the battery ground cable with the ignition turned off. Refer to Removal and Installation

Remove the air filter housing with the Mass Airflow (MAF) sensor and intake tube. Refer to AIR FILTER HOUSING OVERVIEW .

Remove the battery. Refer to Removal and Installation

Remove the battery tray bolts -arrows- and tray.

Remove the engine cover. Refer to ENGINE COVER .

Remove the fuel filter and the auxiliary fuel pump -V393- or fuel pump 2 -V277-. Refer to Auxiliary Fuel Pump -V393- OR Fuel Pump 2 -V277 .

Remove the noise insulation. Refer to Description and Operation .

Drain the coolant. Refer to DRAINING AND FILLING .

Extract the refrigerant from the Air Conditioning (A/C) system. Refer to "A/C Service Station" in DESCRIPTION AND OPERATION .

Remove the lock carrier. Refer to Removal and Installation .

Remove the bolt -arrow- and move the windshield washer fluid reservoir filler tube to the side.

Scheme 307

Remove the coolant expansion tank and lay it on the engine.

Remove the bolt -arrow-, turn the intake tube -A- to the right and remove it.

Scheme 308

Remove the vacuum hoses -1 and 2- for the charge air regulation.

Scheme 309

Disconnect the connectors for the exhaust gas temperature sensor 1 -G235- -1-, the heated oxygen sensor -G39- -3- and for the exhaust gas temperature sensor 4 -G648- -2-.

Scheme 310

Disconnect the exhaust gas temperature sensor 3 -G495- connector -1- (attached behind the bracket).

Scheme 311

Guide the wires out of the mounts on the plenum chamber bulkhead and on the turbocharger.

Remove the vacuum line from the vacuum pump.

Remove the refrigerant line bolt -arrow- from the A/C compressor.

Scheme 312

Remove the refrigerant line from the A/C compressor and move it to the side without bending it.

Open the quick-release couplings for the heater core hoses -arrows- on the plenum chamber bulkhead.

Scheme 313

Remove the nut and the starter positive wire -arrow- from the central electronics and place the wire on the engine.

Scheme 314

Vehicles with a Direct Shift Gearbox (DSG)

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

Turn and unlock the Mechatronic unit connector -arrow- and disconnect it.

Scheme 315

Vehicles with a Manual Transmission

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

Remove the hose/line assembly or plastic hose from the clutch slave cylinder. Refer to SLAVE CYLINDER WITH RELEASE BEARING .

Continuation for all Vehicles

Remove the windshield wiper arms and the plenum chamber cover. Refer to the following

Refer to Removal and Installation

Removal and Installation

Remove the plenum chamber bulkhead. Refer to Description and Operation .

Remove the Engine Control Module (ECM). Refer to Engine Control Module -J623-, WITH AN ANTI-THEFT IMMOBILIZER .

Release the engine wiring harness connector -arrow- and disconnect it from the ECM.

Scheme 316

Disconnect the connectors -1 and 2- on the left longitudinal member.

Scheme 317

Disconnect the ground wire from the transmission.

Open the locking mechanism -A- inside the plenum chamber bulkhead.

Remove the upper part upward and remove the engine wiring harness from the wire guide.

Scheme 318

Disconnect all connectors between the starter, the transmission and the body.

Remove the bolt -arrow- at the top of the particulate filter bracket and loosen the bolt on the cylinder head just one turn.

Scheme 319

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

Remove the drive axles. Refer to Removal and Installation .

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

Scheme 320

Loosen the clamp -1- between the particulate filter and the turbocharger.

Scheme 321

Remove the nuts above the particulate filter mount using the wrench SW 13T10384.

Remove the nuts -arrows- for the particulate filter mount -A- on the crankcase and remove the mount.

Scheme 322

Move the particulate filter to the side and fasten it to the plenum chamber bulkhead.

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

Engage the lifting tackle 3033 as follows and support the engine/transmission subassembly with the shop crane - load cap = 700-122 KG VAS 6100.

Scheme 323

Vibration damper side

1. Position 2.

Flywheel side

1. Position 8.

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

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

Note. When removing the engine/transmission subassembly, guide it out carefully to avoid damaging it.

Lower the engine/transmission subassembly slightly and remove it toward the front.

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

ENGINE, SECURING TO Engine and Transmission Holder VAS 6095

To perform the procedure, secure the engine to the engine and transmission holder VAS 6095 using the universal mounting VAS 6095/1.

Special tools and workshop equipment required

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

Procedure

Remove the transmission.

Engage the lifting tackle 3033 as follows and lift the engine using the shop crane - load cap = 700-1200 KG VAS 6100 from the engine-/gearbox jack V.A.G 1383 A.

Scheme 324

Flywheel side: Position 4.

Vibration damper side: Position 8.

Secure the engine to the engine and transmission holder VAS 6095 using the universal mounting VAS 6095/1.

ENGINE, INSTALLING

Install in the reverse order of removal. When doing this note the following

Servicing the Clutch

1. If the vehicle has a manual transmission, refer to «Clutch»(ref-480947-S07525626832012061900000) .
2. If the vehicle has a Direct Shift Gearbox (DSG), refer to «[For transmission(s) 02E] Clutch»(ref-480913-S02192435252012061900000) .

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

When installing the engine/transmission subassembly, make sure there is enough clearance around the subframe and the radiator.

Adjust the engine and transmission mounts. Refer to ENGINE AND TRANSMISSION MOUNT, ADJUSTING .

Note. Engine and transmission mount tightening specifications. Refer to FASTENER TIGHTENING SPECIFICATIONS . Electrical connections and routing. Refer to Wiring .

Vehicles with a Manual Transmission

Install the hose/line assembly for the hydraulic clutch. Refer to CLUTCH HYDRAULIC HOSE/LINE .

Install the transmission shift mechanism and adjust it if necessary. Refer to SHIFT MECHANISM .

Vehicles with a DSG

Install the transmission selector lever cable and adjust it if necessary. Refer to REMO VAL AND INSTALLATION .

Continuation for all Vehicles

Note. Make sure the particulate filter is free of tension when it is installed. Replace the self-locking nuts, seals, gaskets and clamps.

Install the particulate filter. Refer to PARTICULATE FILTER WITH NOX ABSORPTION CATALYTIC CONVERTER .

Install the drive axles to the transmission. Refer to Removal and Installation

Install the right drive axle heat shield and bolts -arrows-. Refer to Specifications .

Scheme 325

Install the lock carrier. Refer to Removal and Installation .

Install the refrigerant lines to the Air Conditioning (A/C) compressor and condenser without tension.

Charge the A/C system. Refer to "A/C Service Station" in Description and Operation .

Install the battery tray and battery. Refer to Removal and Installation .

Observe the notes after connecting the battery. Refer to Removal and Installation .

Fill the coolant system. Refer to DRAINING AND FILLING .

Fill the fuel system. Refer to FUEL SYSTEM, FILLING AND BLEEDING .

Check the Diagnostic Trouble Code (DTC) memory of each control module. Erase all of the DTC entries that might have occurred during assembly. Refer to the vehicle diagnostic tester.

Check the headlamp adjustment and adjust if necessary. Refer to Diagnosis and Testing .

Tightening Specifications