ENGINE, REMOVING
Special tools and workshop equipment required
- Torque Wrench (5-50 (Nm) -V.A.G 1331
- Torque Wrench (40-200 Nm) -V.A.G 1332
- Engine/Transmission Jack -V.A.G 1383 A
- Spring Type Clip Pliers -VAS 5024 A
- Step Ladder -VAS 5085
- Engine/Trans. Support -T10012
- Cable Tie
For information on securing the engine to the engine stand, refer to ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER VAS 6095 .
Note. To perform this procedure, the ground cable must be disconnected from the battery. See if a coded radio is installed. If so, obtain the antitheft 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.
| CAUTION | When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed. To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components. |
Disconnect the battery Ground (GND) cable with the ignition turned off. Refer to Removal and Installation .
Remove the engine cover/upper air filter housing. Refer to ENGINE COVER/UPPER AIR FILTER HOUSING .
Remove the battery, battery tray bolts -arrows- and tray.
Scheme 286
GTI and Eos
Remove the wiper arms, the plenum chamber cover and the bulkhead plenum chamber. Refer to PLENUM CHAMBER COVER .
Disconnect the engine wiring harness connector from the Engine Control Module (ECM).
Release the pass-through for the engine wiring harness -arrow- and pull it off upward.
Scheme 287
Passat
Remove the windshield wiper arms and plenum chamber cover. Refer to PLENUM CHAMBER COVER .
Disconnect the engine wiring harness connector from the ECM.
Release the pass-through for the engine wiring harness -arrow- and pull it off upward.
Scheme 288
Continuation for all Vehicles
Remove the nut and the cable -arrow- for the generator from the fuse holder.
Scheme 289
Remove the bolt and the ground wire -arrow- from the longitudinal member.
Scheme 290
Open the locking mechanisms for the cable guide on longitudinal member -arrows-.
Scheme 291
Disconnect all harness connectors of the engine wiring harness/body and set down the engine wiring harness on the engine.
| WARNING | Fuel system is under pressure. Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Before loosening the line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line. |
Disconnect the lines -1, 2 and 3-. Press the release buttons.
Scheme 292
GTI and Eos
Disconnect the ventilation line -2-. Remove the Evaporative Emission (EVAP) canister with the hoses upward from the bracket.
Scheme 293
Continuation for all Vehicles
Remove the noise insulation. Refer to Description and Operation .
Remove the left and right front part of the front wheel housing liners.
Scheme 294
Disconnect the charge air hoses -arrows-.
Scheme 295
Remove the right drive axle heat shield bolts -arrows- and shield.
Scheme 296
Remove the right and left drive axles. Refer to Removal and Installation .
Remove the front pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .
Move the lock carrier into the service position. Refer to Description and Operation .
Drain the coolant. Refer to DRAINING AND FILLING .
Evacuate the Air Conditioning (A/C) system. Refer to REFRIGERANT CIRCUIT . .
Disconnect the A/C line -arrow- from the A/C compressor.
Scheme 297
Remove the A/C pipe from the condenser -arrow-.
Scheme 298
Remove the bolts -1 through 3- and remove the pendulum support.
Scheme 299
Disconnect all remaining electrical wires necessary from the engine/transmission and set them aside.
Disconnect all coolant, vacuum- and intake hose connections from the engine.
Vehicles with a Manual Transmission
Remove the shift mechanism from the transmission. Refer to DISASSEMBLY AND ASSEMBLY .
Clamp off the hose/line assembly hose -A- to the slave cylinder using the hose clamps up to 25 mm dia. 3094.
Scheme 300
Pull the hose/line assembly clip -arrow- out as far as the stop.
Remove the hose/line assembly from the slave cylinder breather.
| CAUTION | Do not operate the clutch pedal any more. |
Vehicles with a Automatic Transmission
Remove the selector lever cable from the transmission. Refer to [For transmission(s) 09G] Removal and Installation .
Vehicles with a Direct Shift Gearbox
Disconnect the selector lever cable from the transmission. Refer to SHIFT MECHANISM .
Continuation for all Vehicles
Remove the coolant recirculation pump -V50- bolts -arrows-.
Scheme 301
Install the engine/trans. support -T10012- to the engine/transmission jack -V.A.G 1383 A-.
Install the engine/trans. support -T10012- to the engine as illustrated and tighten the bolt -1- and nut -2- to 20 Nm.
Scheme 302
Gently, lift the engine and transmission using the engine / transmission jack -V.A.G 1383 A-.
Remove the engine mount to engine mount bracket bolts -arrows-.
Scheme 303
Remove the transmission mount to transmission mount bracket bolts -arrows-.
Scheme 304
Note. Use the step ladder -VAS 5085- to remove the bolts. Guide the engine and transmission carefully when lowering to prevent damage to the vehicle body.
Carefully lower the engine with the transmission.
ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER VAS 6095
Special tools and workshop equipment required
- Engine Sling -2024 A
- Shop Crane -VAS 6100
- Engine and Transmission Holder -VAS 6095
Secure the engine to the engine and transmission holder -VAS 6095- when working on it.
Separate the transmission.
Install the engine sling -2024 A- as follows and lift out the engine from the engine/transmission jack -V.A.G 1383 A- using the shop crane -VAS 6100-.
Scheme 305
Belt pulley side: 2nd hole of rail in position 1.
Flywheel side: 1st hole of rail in position 7.
| CAUTION | Use securing pins at hook and drifts in order to prevent damage on engine and on vehicle. |
- The peg positions on the engine sling marked 1 to 4 face the belt pulley.
- The bores in the hole rail are counted from the hook.
Secure the engine to the engine and transmission holder -VAS 6095-.
ENGINE, INSTALLING
Tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .
Install in reverse order of removal. Note the following
| CAUTION | When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed. To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components. |
Insert new centering sleeves for centering the transmission to the cylinder block.
Engage the intermediate plate at the sealing flange and slide it onto the centering sleeves -arrows-.
Scheme 306
Vehicles with a Manual Transmission
Grease the splines of the input shaft lightly using grease for clutch plate splines -G 000 100-.
Inspect and install the clutch and clutch release mechanism. Refer to CLUTCH RELEASE MECHANISM OVERVIEW .
Continuation for all Vehicles
When installing the engine/transmission assembly, check for clearance to the subframe as well as to the radiator.
Align the engine mount as follows
Scheme 307
- There must be a distance of at least 10 mm -a- present 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 -1-.
Install the pendulum support.
Note. For the engine/transmission mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS . Secure electrical connections and routing. .
Install the front exhaust pipe with catalytic converter.
Install the right and left drive axles. Refer to Removal and Installation .
Vehicles with a Manual Transmission
Install the shift mechanism and adjust if necessary. Refer to SHIFT AND SELECTOR CABLES .
Connect the hose/line assembly to the slave cylinder breather. Refer to CLUTCH HYDRAULIC HOSE/LINE .
Vehicles 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 Vehicles
Install the noise insulation. Refer to Description and Operation .
Install the plenum chamber bulkhead (GTI and Eos only), the plenum chamber cover and the windshield wiper arms. Refer to PLENUM CHAMBER COVER .
Connect the battery. Follow the steps after connecting the battery. Refer to Removal and Installation .
Fill with coolant. Refer to DRAINING AND FILLING .
Connect the vehicle diagnosis, testing & info. system VAS 5051 B.
Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries which may have occurred during the assembly.
Perform a road test.
Then, perform a vehicle system test and repair any occurring malfunctions.
Note. Generate a readiness code if the DTC memory was erased. Refer to "Guided Function" in the vehicle diagnostic tester.
Tightening Specifications
| Bolted Connections | Tightening Specification | |
|---|---|---|
| Bolts and Nuts | M6 | 10 Nm |
| M7 | 15 Nm | |
| M8 | 25 Nm | |
| M10 | 40 Nm | |
| M12 | 60 Nm |
Scheme 308
Special tools and workshop equipment required
- Torque Wrench (5-50 (Nm) -V.A.G 1331
- Torque Wrench (40-200 Nm) -V.A.G 1332
- Engine/Transmission Jack -V.A.G 1383 A
- Spring Type Clip Pliers -VAS 5024 A
- Step Ladder -VAS 5085
- Engine/Trans. Support -T10012
Scheme 309
Special tools and workshop equipment required
- Engine Sling -2024 A
- Shop Crane -VAS 6100
- Engine and Transmission Holder -VAS 6095