2.0L - Engine Assembly - Engine Code(s): Cbfa & Ccta (Sedan) (A5 Platform): Other Volkswagen Jetta V

ENGINE AND TRANSMISSION MOUNT, ADJUSTING

Special Tools And Workshop Equipment Required

1. Engine Support Bridge 10-222 A
2. Bracket with Spindle and Hook 10-222 A/10 (Qty: 2)
3. Shackle 10-222 A/12 (Qty: 2)
4. Adapter 10-222 A/13 (Qty: 2)
5. Torque Wrench (5-50 Nm) V.A.G 1331
6. Torque Wrench (40-200 Nm) V.A.G 1332

Procedure

Note. If only the engine mount will be adjusted, the bracket with spindle and hook 10-222 A/10 will be sufficient. It is not necessary to remove the air filter housing, the battery tray and the battery.

Remove the engine cover. Refer to ENGINE COVER .

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

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

Scheme 216

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

Scheme 217

Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

Install the engine support bridge 10-222 A using the following special tools

Scheme 218

1. Bracket with spindle and hook 10-222 A/10 (Qty: 2)
2. Shackle 10-222 A/12 (Qty: 2)
3. Adapter 10-222 A/13 (Qty: 2)

Install the shackles 10-222 A/12 to both front brackets on the engine and hang the bracket with spindle and hook 10-222 A/10.

Support the engine and transmission but do not lift it.

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 hand tighten them.

Scheme 219

Vehicles with a Manual Transmission

Scheme 220

Replace the transmission mount to transmission mount bracket bolts -arrows- one after the other (if this was not already done when the engine was installed) and hand tighten them.

Vehicles with Direct Shift Gearbox (DSG)

Scheme 221

Replace the transmission mount to transmission mount bracket bolts -arrows- one after the other (if this was not already does when the engine was installed) and hand tighten them.

Continuation for all Vehicles

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

Scheme 222

1. Between the engine mount bracket -2- and the right longitudinal member, there must be clearance of 10 mm -a-.
2. The casting edge on the engine mount bracket -2- must be parallel to the engine mount support arm -1- ; dimension -x- must be the same at the front and the rear.

Vehicles with a Manual Transmission

Scheme 223

The edges on the transmission mount bracket -1- and the transmission mount support arm -2- are parallel on the transmission side.

1. Dimension -x- is the same size on both sides.

Vehicles with a DSG

Scheme 224

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

1. Dimension -x- is the same size on both sides.

Continuation for all Vehicles

Tighten the engine and transmission mount bolts to specifications. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .

Further installation is in the reverse sequence of removal.

ENGINE, REMOVING

Special Tools And Workshop Equipment Required

1. Tension Strap T 10038
2. Locking Pin T10060 A
3. Engine Support T10359
4. Torque Wrench (5-50 Nm) V.A.G 1331
5. Torque Wrench (40-200 Nm) V.A.G 1332
6. Engine-/Gearbox Jack V.A.G 1383 A
7. Step Ladder VAS 5085
8. Engine Bung Set VAS 6122
9. Drip Tray for VAS 6100 VAS 6208 or V.A.G 1306
10. Hose Clip Pliers VAS 6362
11. Cable Tie

Note. To perform this procedure, the battery ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, 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. Seal off removed fuel, ventilation and vacuum lines so no dirt enters the system. Leave the key in the ignition lock to prevent the steering wheel from locking.

Check the Diagnostic Trouble Code (DTC) memory for all control modules before removal.

Remove the engine cover. Refer to ENGINE COVER .

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

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

Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09

Remove the charge air pipe from the noise generator, if equipped. Refer to CHARGE AIR PIPE FROM NOISE GENERATOR .

Disconnect the engine harness connector from the Engine Control Module (ECM). Refer to one of the following

1. «ENGINE CONTROL MODULE, THROUGH 10.08»(ref-479511-S05437466552012061300000) .
2. «ENGINE CONTROL MODULE, FROM 11.08»(ref-479511-S07074592512012061300000) .

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

Scheme 225

Remove the E-box cover by sliding both latches in the -direction of the arrow-.

Scheme 226

Remove the nuts and the wire from the generator -A- and the wire from the battery -B- from the fuse holder.

Scheme 227

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

Scheme 228

Free up the electrical connector -1- and disconnect it.

Scheme 229

Open the underlying wiring guide bracket -2-.

Remove the ECM wiring harness out of the wiring router and lay it on the engine.

GLI from MY 12

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

Scheme 230

Remove the nut and the wire -2- and free it up.

Scheme 231

Vehicles with a Manual Transmission

Remove the shift mechanism from the transmission. Refer to [For transmission(s) 02Q] SHIFT MECHANISM .

Use hose clamps up to 25 mm dia.3094 to pinch off the hose leading to the clutch master cylinder.

Scheme 232

Pull the clip -arrow- for the line -A- out, up to the stop.

Scheme 233

Disconnect the line -A- from slave cylinder breather and seal it off.

Vehicles with Direct Shift Gearbox (DSG)

Disconnect the selector lever cable from the transmission. Refer to [For transmission(s) 02E] SELECTOR LEVER CABLE, THROUGH 02.09 .

Continuation for all Vehicles

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

Scheme 234

Disconnect the connector -2-.

Scheme 235

Remove the fan shroud upper bolts -upper arrows-.

Scheme 236

Loosen the hose clamp -2-.

Scheme 237

Remove the bolt -4-.

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

Open the cap on the coolant expansion tank.

Remove the front wheels.

Remove the noise insulation. Refer to Description and Operation .

Remove the front part of the wheel housing liners and/or the front wheel housing liners. Refer to Removal and Installation .

Remove the charge air hoses -arrows-.

Scheme 238

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

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

Remove the fan shroud downward.

Disconnect the connector -2- from the engine coolant temperature sensor on radiator -G83-.

Scheme 239

Note. Collect the leaking coolant in a clean container for disposal or reuse.

Place the drip tray for VAS 6100 VAS 6208 or V.A.G 1306 under the engine.

Drain the coolant. Refer to DRAINING AND FILLING .

Reposition the clamps -1 and 2- and disconnect the coolant hoses.

Scheme 240

Disconnect the lines and catch any fuel coming out with a cloth.

Scheme 241

1. Ventilation line (press the circlip to release the line).
2. Vacuum line (press the circlip to release the line), if equipped.
3. Fuel supply line (pull the circlip upward to release the line).

Remove the upper coolant hose -arrow- from the radiator by removing the securing clip.

Scheme 242

Disconnect the heater core coolant hoses -arrows-.

Scheme 243

From the top, remove the front exhaust pipe with catalytic converter to turbocharge nuts -arrows-.

Scheme 244

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

Scheme 245

Remove the drive axles. Refer to Removal and Installation

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 A/C compressor.

Scheme 246

Remove the A/C compressor bolts -arrows-.

Tie up the compressor with the refrigerant lines attached to the longitudinal member.

Remove the generator -C-. Refer to Removal and Installation .

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

Scheme 247

Note. The after-run coolant pump stays in the installed position.

First, remove the pendulum support bolt -1-.

Scheme 248

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

Scheme 249

Disconnect the vacuum hoses -arrows-.

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

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

Install the engine Support T10359 to the cylinder block using the bolt -1- and tighten it to approximately 20 Nm.

Scheme 250

Note. The threaded hole for the bolt -1- secures the after-run coolant pump.

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

Slightly lift the engine/transmission assembly.

Note. Use the step ladder VAS 5085 to remove the engine/transmission mount bolts.

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

Vehicles with a Manual Transmission

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

Vehicles with DSG

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

Continuation for all Vehicles

Note. Verify that all hoses and lines between the engine, transmission and body have been disconnected. While lowering, carefully guide the engine/transmission assembly in order to prevent damages.

Vehicles with DSG

Pay attention to the selector lever cable.

Continuation for all Vehicles

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

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

ENGINE, SECURING TO THE Engine and Transmission Holder VAS 6095

Special Tools And Workshop Equipment Required

1. Engine Sling 2024 A
2. Shop Crane-Load Cap = 700-1200 KG VAS 6100
3. Engine and Transmission Holder VAS 6095

Conditions

1. The engine and transmission are removed and are secured to the engine-/gearbox jack V.A.G 1383 A with the engine Support T10359.

Procedure

Separate the engine from the transmission. Refer to ENGINE AND TRANSMISSION, SEPARATING AND ASSEMBLING .

Install the engine sling 2024 A to the engine and use the shop crane-load cap = 700-1200 KG VAS 6100 to lift the engine from the engine-/gearbox jack V.A.G 1383 A as shown below.

Scheme 251

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

ENGINE, INSTALLING

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

Insert new centering sleeves in the cylinder block.

Engage the intermediate plate at the sealing flange and slide it onto the alignment sleeves -arrows-.

Scheme 252

Vehicles with a Manual Transmission

Servicing the clutch, refer to [For transmission(s) 02Q] Clutch .

Vehicles with Direct Shift Gearbox

Servicing the clutch, refer to [For transmission(s) 02E] Clutch .

Replace the needle bearings in the crankshaft. Refer to CRANKSHAFT NEEDLE BEARINGS .

Pay attention to the selector lever cable.

Continuation for all Vehicles

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

Adjust the engine/transmission mounts, refer to one of the following

1. Jetta/GLI for MY 08 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09. Refer to «ENGINE AND TRANSMISSION MOUNT, ADJUSTING»(ref-479583-S21799287812012061300000) .

Note. Engine and transmission mount tightening specifications. Refer to ENGINE AND TRANSMISSION MOUNT OVERVIEW .

Vehicles with a Manual Transmission

Install the transmission shift mechanism. Refer to [For transmission(s) 02Q] SHIFT MECHANISM .

Vehicles with DSG

Install the transmission selector lever cable. Refer to [For transmission(s) 02E] SELECTOR LEVER CABLE, THROUGH 02.09 .

Continuation for all Vehicles

Electrical connections and routings. Refer to Wiring and Wiring .

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

Fill the coolant. Refer to DRAINING AND FILLING .

Check the Diagnostic Trouble Code (DTC) memories of all control modules and erase any DTC entries which may have occurred during the assembly. Refer to On Board Diagnostic (OBD) in the vehicle diagnostic tester.

Perform a road test.

Note. Observe the safety precautions that apply to road tests. Refer to "special testing equipment" in SAFETY PRECAUTIONS .

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

Note. If the DTC memory was erased, the readiness code must be generated again.

Tightening Specifications