Engine Assembly: Other Volkswagen Tiguan I

ENGINE/TRANSMISSION MOUNT, ADJUSTING

Note. Always use two brackets with spindles and hooks 10-222 A/10. Otherwise the engine support bridge 10-222 A will have a tendency to tip.

Special tools and workshop equipment required

1. Engine Support Bridge 10-222 A
2. Adapter 10-222 A/22 (Qty. 2)
3. Engine Support Adapter 10-222 A/3 (Qty. 2)
4. Bracket with Spindle and Hook 10-222 A/10 (Qty. 2)
5. Shackle 10-222 A/12
6. Lifting Eyebolt 3368 (For automatic transmissions only)

Procedure

Remove the engine cover. Refer to ENGINE COVER .

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

With the ignition turned off, remove the ground wire -arrow- from the battery.

Scheme 158

Remove the battery. .

Remove the battery tray bolts -arrows- and tray.

Scheme 159

with a Automatic Transmission

Scheme 160

Install the lifting eyelet 3368 to the transmission mount bracket as shown.

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

Scheme 161

1. Adapter 10-222 A/22, Qty. 2
2. Engine support adapter 10-222 A/3, Qty. 2
3. Bracket with spindle and hook 10-222 A/10, Qty. 2
4. Shackle 10-222 A/12

with a Manual Transmission

Scheme 162

Remove the shift mechanism from the transmission. Refer to [For transmission(s) 0A6] Removal and Installation .

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

1. Adapter 10-222 A/22, Qty. 2
2. Engine support adapter 10-222 A/3, Qty. 2
3. Bracket with spindle and hook 10-222 A/10, Qty. 2
4. Shackle 10-222 A/12

Continuation for All

Support the engine and the 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 tighten them hand tight.

Scheme 163

with a Manual Transmission

Scheme 164

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

with a Automatic Transmission

Scheme 165

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

Continuation for All

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

Adjust the engine and transmission mounts and hand tighten the bolts.

Engine Mount

Scheme 166

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-.

Transmission Mount

Scheme 167

1. The edges of the transmission mount support arm -1- and transmission mount -2- are parallel.
2. Dimension -x- is the same size on both sides of the mount.

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

Further installation is in the reverse order of removal.

ENGINE, REMOVING

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Engine Sling 2024 A
3. Engine-/Gearbox Jack V.A.G 1383 A
4. Hose Clip Pliers V.A.G 1921
5. Step Ladder VAS 5085
6. Drip Tray for VAS 6100 VAS 6208
7. Engine Support T10359
8. Hose Clip Pliers VAS 6362
9. Engine Bung Set VAS 6122
10. Pins T10359/2
11. Transmission Support 3282

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 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.

Check the Diagnostic Trouble Code (DTC) memories of all control modules before removing the engine. Refer to the vehicle diagnostic tester.

Disconnect the battery Ground (GND) cable with the ignition turned off. .

Remove the engine cover. Refer to ENGINE COVER .

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

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

Remove the wiper arms. Refer to Removal and Installation .

Remove the plenum chamber cover. Refer to one of the following

GTI (2008 through 2009), refer to Description and Operation .

Passat, refer to "Flush Bonded Windows" in Description and Operation

Tiguan, refer to "Moldings and Trim" in Description and Operation .

CC, refer to Removal and Installation .

Eos and GTI (from 2010), refer to Description and Operation .

GTI and Eos

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

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

Passat and CC

Disconnect the engine wiring harness connector from the ECM. Refer to one of the following

Tiguan

Disconnect the engine wiring harness connector from the ECM. Refer to ENGINE CONTROL MODULE J623 .

Continuation for All

Scheme 168

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

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

Scheme 169

Remove the nut -A-, the cable from the generator and the cable from the battery -B- from the fuse holder.

Scheme 170

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

Scheme 171

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

Scheme 172

Free up the electrical connector -1- and disconnect.

Scheme 173

Open the underlying wiring guide bracket -2-.

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

with a Manual Transmission

Remove the shift mechanism from the transmission. Refer to [For transmission(s) 0A6] Removal and Installation .

Clamp off the hose leading to the master cylinder using the hose clamp up to 25 mm dia. 3094.

Scheme 174

Pull out the clip -arrow- for the hose/line assembly.

Scheme 175

Pull the hose/line assembly out of the slave cylinder and seal it off.

with a Automatic Transmission

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

with a Direct Shift Gearbox (DSG®)

Remove the selector lever cable from the transmission. refer to [For transmission(s) 0A6] Removal and Installation .

Tiguan, with a Automatic Transmission

Remove the transmission oil cooler lines from the transmission. Refer to [For transmission(s) 09M] Removal and Installation .

Continuation for All

Disconnect the connector -2-.

Scheme 176

Remove the fan shroud upper bolts -upper arrows-.

Scheme 177

Loosen the hose clamp -2-.

Scheme 178

Remove the bolt -4-.

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

Open the coolant expansion tank cap.

Remove the noise insulation. Refer to one of the following

GTI and Tiguan, refer to Description and Operation

Eos and Passat, refer to "Noise Insulation" in Removal and Installation .

CC, refer to "Noise Insulation" in Description and Operation

Remove the front part of the wheel housing liner or the entire front wheel housing liner. Refer to Wheel Housing Liner .

Remove the charge air hoses -arrows-.

Scheme 179

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

Remove the fan shroud downward.

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

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

Scheme 180

Place the drip tray for VAS 6100 VAS 6208 under the engine.

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

Remove the coolant hoses -1 and 2-.

Scheme 181

Disconnect the lines at the bracket.

Scheme 182

1 - Vent line

2 - Vacuum line

3 - Fuel supply line

GTI, Passat, CC and Eos

Scheme 183

Remove the upper coolant hose -arrow- from the radiator.

Tiguan

Remove the right coolant hose from the radiator and disconnect the left coolant hose from the radiator.

Continuation for All

Scheme 184

Remove the bracket slightly in order to remove the heater core hoses -arrows-.

From above, remove the front exhaust pipe to turbocharger/exhaust manifold nuts -arrows-.

Scheme 185

Disconnect the vacuum hoses -arrows-.

Scheme 186

with Front Wheel Drive (FWD)

Scheme 187

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

Continuation for All

Remove the drive axles. Refer to Removal and Installation .

To release the tension on the ribbed belt, turn the tensioner in the -direction of the arrow- from underneath.

Scheme 188

Secure the belt tensioner using the locking pin T10060 A.

Remove the ribbed belt.

Disconnect the connector -1- from the A/C compressor regulator valve.

Scheme 189

Remove the A/C compressor bolts -arrows-.

Secure the A/C compressor with the refrigerant lines attached to the longitudinal member.

GTI and Eos

Remove the generator. .

Continuation for All

Scheme 190

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

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

First, remove the bolt -1-, then the bolts -2 and 3- then the pendulum support.

Scheme 191

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

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

Scheme 192

1. Install the pin T10359/2 to the engine support T10359 and then install the transmission support.

Attach the engine support T10359 -1- to the engine and guide it into the mount.

Seat the tensioner -3- in order to prevent the engine from tilting out of the engine support T10359.

Secure the engine support T10359 -1- to the cylinder block using the bolt -3- and tighten it to approximately 20 Nm.

Scheme 193

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

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

Slightly lift the engine and transmission.

Note. Use a step ladder VAS 5085 to remove the engine and transmission mount to bracket bolts.

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

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

Note. Verify that all hose and wire connections between the engine, transmission and body have been disconnected. To prevent damage, carefully guide the engine and transmission when lowering.

with a DSG®

1. Pay attention to the selector lever cable.

Continuation for All

Move the engine and transmission as far as possible to the left and slowly lower it.

Secure the engine onto the engine and transmission holder VAS 6095 when working on it. Refer to ENGINE, SECURING TO THE ENGINE/TRANSMISSION HOLDER .

ENGINE, SECURING TO THE ENGINE/TRANSMISSION HOLDER

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

Requirements

1. The engine/transmission assembly removed and secured to the engine support T10359.

Procedure

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

Install the engine sling 2024 A as illustrated 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 194

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

ENGINE, INSTALLING

For the engine/transmission mount tightening specifications, refer to one of the following

GTI, Eos, Passat and CC, refer to .

Tiguan, refer to ENGINE/TRANSMISSION MOUNT OVERVIEW .

Install in the reverse order of removal. Note the following

Insert new alignment sleeves for centering the engine/transmission in the cylinder block.

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

Scheme 195

with a Manual Transmission

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

Inspect and install the clutch and clutch mechanism. Refer to [For transmission(s) 0A6] Clutch .

with a Direct Shift Gearbox (DSG®)

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

Adjust the selector lever cable after installing. Refer to [For transmission(s) 0A6] Description and Operation .

Continuation for All

Make sure there is enough clearance to the subframe and radiator when installing the engine/transmission subassembly.

Adjust the engine/transmission mounts. Refer to one of the following

GTI and Eos, refer to .

Passat and CC, refer to .

Tiguan, refer to ENGINE/TRANSMISSION MOUNT, ADJUSTING .

Note. For the engine/transmission mount tightening specifications, refer to one of the following: GTI, Eos, Passat and CC, refer to . Tiguan, refer to ENGINE/TRANSMISSION MOUNT OVERVIEW .

Electrical connections and routing, refer to Wiring .

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 road test.

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

Note. Generate a readiness code if the DTC memory was erased. Refer to "Guided Functions" in the vehicle diagnostic tester.

Tightening Specifications