2.5L - Engine Assembly - Engine Code(s): Cbta & Cbua: Other Volkswagen Golf Mk7

ENGINE COVER

The engine cover is a single component with the air filter housing. Refer to ENGINE COVER WITH AIR FILTER .

ENGINE, REMOVING

Note. If the engine oil must be drained because of work performed on the removed engine, it should be drained with the engine 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.

Special tools and workshop equipment required

1. Hose Clip Pliers VAS 6340
2. Hose Clip Pliers VAS 6362
3. Engine-/Gearbox Jack V.A.G 1383 A
4. Tensioning Strap T10038
5. Step Ladder VAS 5085
6. Engine Holder Bracket T03000
7. Cable Ties
8. Foam Mat

For information on securing the engine to the engine stand, refer to ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095 .

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 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.

Remove the engine cover with air filter. Refer to ENGINE COVER WITH AIR FILTER .

Remove the battery. Refer to Battery .

Remove the cover -1- for the E-box and remove the wire -2-.

Scheme 265

Remove the battery tray bolts -arrows- and remove the battery tray from the vehicle.

Disconnect the engine wiring harness connector from the Engine Control Module (ECM).

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

Scheme 266

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

Scheme 267

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

Scheme 268

Disconnect the ground cable -1- and the starter connections -2 and 5-.

With a Automatic Transmission

Disconnect the connector -6- from the multifunction switch.

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

With a Manual Transmission

Remove the shift mechanism from the transmission. Refer to [For transmission(s) 0A4] Removing .

Remove the brace -1-.

Scheme 269

Remove the slave cylinder bolts -arrows- and cylinder, set it aside, do not open line system.

Disconnect the connector for the backup light switch on the transmission.

Continuation for All

Disconnect the vacuum hose from the brake booster.

Disconnect the connector from the heated oxygen sensor -G39- on the bulkhead and free up the electric wiring harness.

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

Remove the front section of the right wheel housing liner. Refer to Removal and Installation .

Move the lock carrier into the service position. Refer to Description and Operation .

So that it is possible to remove the engine without opening the refrigerant circuit

Remove the ribbed belt. Refer to RIBBED BELT .

Unbolt the Air Conditioning (A/C) compressor from the accessory bracket. Refer to "Refrigerant Circuit Components" in Removal and Installation .

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

Tie up the A/C compressor with the refrigerant hoses still connected.

Disconnect the connection from the generator and free up the wiring harness.

Remove the 4 exhaust pipe with catalytic converter to exhaust manifold nuts -2- and the suspended mount bolts -3-.

Scheme 270

Remove the exhaust pipe with catalytic converter -1- from the manifold and tie up firmly to the side. Refer to EXHAUST PIPE WITH CATALYTIC CONVERTER .

Note. The coupling element in the exhaust pipe with catalytic converter must not be bent more than 10°, otherwise it may be damaged.

Remove the right drive axle and remove the left drive axle from the transmission. Refer to Removal and Installation .

Remove the pendulum support.

Disconnect the ventilation line -1-, vacuum line -2- and fuel supply line -3-. Press in the securing ring to disengage the lines.

Scheme 271

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

Remove the bolt -2- and move the windshield washer fluid reservoir -1- toward the front.

Scheme 272

Remove the bolts -6- and disconnect the connector -3-.

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

Note. Slightly loosen the bolts on the engine and transmission mounts before lifting the vehicle.

Disconnect the coolant lines at the radiator and heater core (quick acting couplings).

Install the engine holder bracket T03000 as follows

Scheme 273

1. Remove the pin T03000/3 from the bracket.
2. Mount the engine holder bracket T03000 with the pin T03000/4 to the cylinder block and tighten the bolts -1 and 2- hand tight.
3. Then, install the pin T03000/3 and tighten it to 20 Nm.
4. Then, tighten the bolts -1 and 2- to 25 Nm.

Place the engine-/gearboxjack V.A.G 1383 A under the engine holder bracket T03000 and lift the engine/transmission assembly slightly.

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

Scheme 274

Note. Remove the rear bolt -2- through a hole in the wheel housing.

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

Scheme 275

Note. Use the step ladder VAS 5085 to remove the mount bolts. The engine/transmission assembly must be guided with care to prevent damage while lowering it.

Lower the engine/transmission assembly carefully downward.

WITH A AUTOMATIC TRANSMISSION

Special tools and workshop equipment required

1. Shop Crane - Load Cap = 700-1200 KG VAS 6100
2. Shackle 10-222 A/12
3. Crankshaft Adapter T03003
4. Socket SW 15V/175
5. Hose Clamps up to 25 mm Dia. 3094
6. Hose Clamps up to 40 mm 3093

Conditions

1. The engine and transmission assembly is removed and secured to the engine holder bracket T03000.

Separating

Remove the bracket -1- from the starters upper stud bolt -arrow-.

Scheme 276

Remove the starter upper stud bolt.

Note. Mark the coolant hoses on the transmission fluid cooler to prevent mixing them up when installing them again later.

Clamp off the coolant hoses to the transmission fluid cooler using the hose clamps up to 25 mm dia. 3094 and the hose clamps up to 40 mm 3093.

Scheme 277

Open the spring clamps -A- and remove the coolant hoses -B and C- from the cooler.

Seal the coolant hoses and connections with plugs from the engine bung set VAS 6122.

Remove the upper transmission to engine bolts -arrows- using a 12 point swivel socket -A-.

Scheme 278

Turn the cap -1- in the -direction of the arrow- and remove it.

Scheme 279

Remove the 6 torque converter nuts using the socket SW 15V/175.

Scheme 280

Rotate the engine in engine rotation direction -arrow- an additional 60° turn using the crankshaft adapter T03003.

Scheme 281

Note. The torque converter will be pulled out when the transmission is separated from the engine if all 6 nuts are not removed! Counter hold the vibration damper using the crankshaft adapter T03003 when loosening the nuts on the torque converter.

Remove the selector lever cable bracket from the transmission.

Scheme 282

Support the transmission using the shop crane - load cap = 700-1200 KG VAS 6100 and the Shackle 10-222 A/12 but do not lift it.

Scheme 283

Remove the last transmission to engine bolt.

Separate the transmission from the engine. Push the torque converter off of the engine drive plate at the same time.

Note. Secure the torque converter from falling out.

Assembling

Assemble in reverse order of removal. Pay attention to the tightening specifications

1. Vehicles with an automatic transmission, refer to «[For transmission(s) 09G] Removal and Installation»(ref-480956-S05966913702012061900000) .

WITH A MANUAL TRANSMISSION

Special tools and workshop equipment required

1. Shackle 10-222 A/12
2. Shop Crane - Load Cap = 700-1200 KG VAS 6100
3. Torque Wrench (40-200 Nm) V.A.G 1332

Conditions

1. The engine and transmission assembly is removed and secured to the engine holder bracket T03000.

Separating

Remove the starter. Refer to Removal and Installation

Disconnect all electrical connections from the transmission to the engine and free them up.

Support the transmission using the shop crane - load cap = 700-1200 KG VAS 6100 and the shackles 10-222 A/12 but do not lift it.

Remove the upper transmission to engine bolts.

Support the transmission using the shop crane - load cap = 700-1200 KG and remove the last bolts.

Remove the lower bolts connecting the engine and transmission.

Separate the transmission from the engine; when doing this, guide the transmission.

Assembling

Assemble in reverse order of removal. Pay attention to the tightening specifications

1. Vehicles with an manual transmission, refer to «INSTALLING»(ref-480999-S27641055562012061900000) .

ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Shop Crane - Load Cap = 700-1200 KG VAS 6100
3. Engine and Transmission Holder VAS 6095
4. Engine Lateral Bracket T03001
5. Transport Arm T03002

When performing work, secure the engine using the engine lateral bracket T03001 to the engine and transmission holder VAS 6095.

Remove the transmission. Refer to one of the following

[For transmission(s) 0A4] Removing .

[For transmission(s) 09G] Removal and Installation .

Pull off the clip -1- for the electric wiring harness, remove the bolts -3- and then remove the cover -2-.

Scheme 284

Disconnect the harness connectors -1 and 2- and remove the bolts -arrows- at the Secondary Air Injection (AIR) valve.

Scheme 285

Install the transport arm T03002 as shown.

Scheme 286

The pin -1- engages in the cylinder block. Tighten the knurled thumb screw -2- hand tight.

Install the engine lateral bracket T03001.

Scheme 287

Tighten the bolts -1 and 3 - to 40 Nm, and the bolt -2- to 25 Nm.

Note. The bolts are designed so that they cannot be lost. When removing, the engine lateral bracket T03001 must be held tensioned in the direction of withdrawal, otherwise the bolt -1- cannot be unscrewed.

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

Scheme 288

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

ENGINE, INSTALLING

Install in reverse order of removal. Note the following

With a Manual Transmission

Grease the splines of the input shaft lightly with grease for clutch plate splines G 000 100.

Install the clutch and the clutch mechanism.

Continuation for All

Secure the engine and transmission mounts to the engine, shake the engine and transmission assembly to align it and tighten the mount bolts.

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

Install the exhaust pipe with catalytic converter. Refer to EXHAUST PIPE WITH CATALYTIC CONVERTER .

Install the right drive axle and the left drive axle to the transmission. Refer to Removal and Installation .

Install the pendulum support. Refer to Specifications .

Install the Air Conditioning (A/C) compressor. Refer to "Refrigerant Circuit Components" in Removal and Installation .

Install the ribbed belt. Refer to RIBBED BELT .

Install the noise insulation. Refer to Description and Operation .

With a Manual Transmission

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

Install the clutch slave cylinder. Refer to [For transmission(s) 0A4] Removal and Installation .

With a Automatic Transmission

Install the selector lever cable and adjust if necessary. Refer to [For transmission(s) 09G] Removal and Installation .

Continuation for All

Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

Install the Engine Control Module (ECM).

Install the battery. Refer to Removal and Installation .

Adapt the ECM. Refer to "Guided Functions" in the vehicle diagnostic tester.

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

Then, end "Guided Fault Finding".

Observe the safety precautions that apply to road tests.

Perform a road test.

After that perform the vehicle system test again and repair any occurring malfunctions.

Tightening Specification