3.6L - Engine Assembly - Engine Code(s): Blv: Other Volkswagen Passat B6

ENGINE, REMOVING

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine Support T40074
3. Torque Wrench (5-50 Nm) V.A.G 1331
4. Torque Wrench (40-200 Nm) V.A.G 1332
5. Engine/Transmission Jack V.A.G 1383 A
6. Step Ladder VAS 5085
7. Hose Clip Pliers VAS 5024 A
8. Engine and Transmission Holder VAS 6095
9. Engine Support 3269
10. Shop Crane VAS 6100
11. Drip Tray for VAS 6100, VAS 6208 or V.A.G 1306
12. Parts Trolley V.A.G 1698
13. Engine Bung Set VAS 6122
14. Cable Tie

The engine with transmission is removed downward.

Check the Diagnostic Trouble Code (DTC) memories for all the control modules. Refer to the vehicle diagnostic tester.

Note. All cable ties which are opened or cut off when removing the engine, must be replaced in the same position when installing the engine. Leave the key in the ignition lock to prevent the steering lock from engaging. It is advisable to remove the front wheels before removing the engine/transmission assembly. The vehicle can be lowered on the hoist until the cover plates for the brake discs are just above the floor. This enables the most ergonomic work position regarding accessibility of components in the engine compartment. When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing the engine. To prevent damage to the removed components, use the parts trolley V.A.G 1698 for storage.

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

Completely remove the air filter housing with the connecting hose to the throttle valve control module -J338-. Refer to AIR FILTER HOUSING OVERVIEW .

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

Remove the windshield wiper arms and plenum chamber cover. Refer to WIPER ARMS and PLENUM CHAMBER COVER .

Vehicles with a Engine Control Module (ECM) equipped with the Anti-Theft Immobilizer

Remove the locking plate or locking bracket from the ECM. Refer to Engine Control Module -J623 .

Continuation for all Vehicles

Disconnect the engine wiring harness connector from the ECM.

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

Scheme 216

Remove the nut and the generator wire -arrow- from the fuse holder.

Scheme 217

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

Scheme 218

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

Scheme 219

Disconnect all harness connectors for the engine wiring harness/body and set down the engine wiring harness on the engine.

Disconnect the oxygen sensor connectors -1 through 4- at the bulkhead and free up the wires

Scheme 220

1 - Heated Oxygen Sensor (HO2S) -G39-, 6 pin harness connector (black)

2 - Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130-, 4 pin harness connector (black)

3 - Heated Oxygen Sensor (HO2S) 2 -G108-, 6 pin harness connector (brown)

4 - Oxygen Sensor (O2S) 2 after Three Way Catalytic Converter (TWC) -G131-, 4 pin harness connector (brown)

Note. On vehicles with All Wheel Drive (AWD), the connectors for the O2S after TWC -2- and the O2S 2 after TWC -4- are secured to the underbody.

Disconnect all connectors from the transmission.

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

Disconnect the selector lever cable -1- from the selector shaft. Then pull the selector lever cable out of the bracket -2-.

Scheme 221

Disconnect the ventilation line -1-, the vacuum line -2- and the fuel supply line -3-. Press the release buttons to do this.

Scheme 222

Disconnect the vacuum line from the brake booster.

Disconnect all other vacuum and intake hose connections from the engine.

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

Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open and close the cap on the expansion tank, to relieve the cooling system pressure.

Remove the fan shroud and fans. Refer to FAN SHROUD WITH FANS .

Remove the lower sections of the front wheel housing liners. Refer to Removal and Installation .

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

Remove the wire bracket for the oil level thermal sensor from the subframe.

Note. To prevent damage to the Air Conditioning (A/C) condenser and the refrigerant lines and hoses, do not stretch, kink or bend the lines and hoses.

In order to remove and install the engine without opening the refrigerant circuit

Remove the ribbed belt. Refer to RIBBED BELT .

Unbolt the A/C compressor from the accessory bracket. Refer to Removal and Installation .

Secure the A/C compressor to the lock carrier so that the refrigerant lines/hoses are not burdened.

Remove the drive axle heat shield for the right drive axle.

Remove the drive axles. Refer to Removal and Installation .

Vehicles with All Wheel Drive (AWD)

Unbolt the driveshaft front flexible disc from the transmission. Refer to DRIVESHAFT, THROUGH CALENDAR WEEK 26.07 .

Continuation for All Vehicles

Remove the front exhaust pipes with catalytic converters, refer to one of the following

AWD, refer to FRONT EXHAUST PIPES WITH CATALYTIC CONVERTERS AND FRONT MUFFLERS .

Front Wheel Drive (FWD), refer to FRONT EXHAUST PIPES WITH CATALYTIC CONVERTERS AND FRONT MUFFLERS .

Note. Do not bend the decoupling elements of the exhaust pipes more than 20° or they could be damaged. Two technicians are needed to perform the removing procedure.

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

Scheme 223

Drain the coolant. Refer to DRAINING AND FILLING .

Disconnect the coolant hoses from the engine using spring type clip pliers VAS 5024A.

Remove the transmission oil line bolt -arrow- from the transmission. Catch any leaking transmission oil.

Scheme 224

Install the engine support T40074 to the engine/transmission jack V.A.G 1383 A.

Remove the adapter T40074/1 from the engine support T40074 and install it to the cylinder block with a nut -1-.

Scheme 225

Position the engine support T40074 on the engine as illustrated and install the adapter T40074/1 to the engine support T40074 -2-.

Scheme 226

Tighten the engine support T40074 to the exhaust side of the cylinder block with two M10 x 25 bolts -arrows- as illustrated and tighten them to 20 Nm.

Scheme 227

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 228

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

Scheme 229

Note. Use the step ladder VAS 5085 to remove the bolts. Carefully guide the engine with transmission, when lowering it, to prevent damage to the bodywork.

Carefully lower the engine with transmission.

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER VAS 6095

Secure the engine to the engine and transmission stand VAS 6095 when working it.

Procedure

Remove the transmission.

After separating the transmission from the engine, secure the torque converter to prevent it from falling out.

Install the lifting tackle 3033 as follows and lift the engine from the engine/transmission jack V.A.G 1383 A using the shop crane VAS 6100.

Scheme 230

Vibration damper side: Position 3.

Flywheel side: Position 11.

Using the Engine/Transmission Holder VAS 6095 with Universal Mounts

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

Scheme 231

Using the Engine Support 3269

Install the engine support 3269 to the cylinder block as shown.

Scheme 232

ENGINE, INSTALLING

Installation is performed in the reverse order of removal, noting the following

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

Align the engine mount as follows

Scheme 233

1. There must be a distance of at least 10 mm -a- present 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-.

Tighten the bolts for the engine mount to the engine mount bracket. Tightening specification: 60 Nm + 90° (1/4) additional turn.

Install the pendulum support.

Note. For the engine/transmission mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .

Install the front exhaust pipe with catalytic converter, refer to one of the following

All Wheel Drive (AWD), refer to FRONT EXHAUST PIPES WITH CATALYTIC CONVERTERS AND FRONT MUFFLERS .

Front Wheel Drive (FWD), refer to FRONT EXHAUST PIPES WITH CATALYTIC CONVERTERS AND FRONT MUFFLERS .

Install the drive axles. Refer to Removal and Installation .

Install the drive axle heat shield.

Secure electrical connections and routing. .

Install the Air Conditioning (A/C) compressor to the bracket. Refer to Description and Operation .

If necessary, fill the transmission with fluid. Refer to General Information .

Connect the ventilation line -1-, the vacuum line -2- and the fuel supply line -3-.

Install the ribbed belt. Refer to RIBBED BELT .

Install the noise insulation. Refer to Description and Operation .

Fill with coolant. Refer to DRAINING AND FILLING .

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 and generate the readiness code. Refer to "Guided Function" in the vehicle diagnostic tester.

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. Refer to "Guided Function" in the vehicle diagnostic tester.

Tightening Specifications

Note. For the engine/transmission mount tightening specifications, refer to FASTENER TIGHTENING SPECIFICATIONS .