Engine, Removing

Special tools and workshop equipment required

Adapter :T10359/3
Engine/Gearbox Jack - Pin :T10359/2
Engine and Gearbox Jack :VAS 6931
Engine/Gearbox Jack - Engine Support :T10359A
Transmission Support - Mounting Plate 59 :3282/059
Engine Bung Set :VAS 6122

The engine is removed downward together with the transmission.

In the following procedure use the Engine Bung Set :VAS 6122 .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

Vehicles with luggage compartment battery:

-- Remove the air filter housing mount.

Continuation for all vehicles

Vehicles with a battery in the engine compartment battery:

-- Remove the air filter housing. Refer to Air Filter Housing, Removing and Installing .

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Open the retainer in -direction of the arrow A- and the cap in -direction of the arrow B-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut -1- and free up the B+ wire.

-- Remove the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

Continuation for all vehicles

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -2- and free it up.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connectors -1- from the Engine Control Module -J623-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector -3-.

-- Free up the wire -2-.

-- Refer to DRAIN THE COOLANT .

-- Disconnect the connector -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the bracket -2- and free up the fuel hoses -3-.

-- Release the hook -4- and put aside the coolant expansion tank -5-.

CAUTION:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Separate the connector couplings -1- and -2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the starter. Refer to STARTER, REMOVING AND INSTALLING .

Vehicles with Manual Transmission:

-- Remove the cable bracket and move to the side with the cables. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

-- Disconnect the connectors -1- and -2-.

Fig 1: Identifying Park/Neutral Position Switch

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the clip -1- as far as the stop.

Fig 2: Bleeder -3- at clutch slave cylinder, removing and installing

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the breather -3- from the transmission.

Continuation for all vehicles

Vehicles with Dual-Clutch Transmission:

-- Turn the connector -1- in -direction of the arrow- and disconnect.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pry out the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SHIFT MECHANISM, REMOVING AND INSTALLING .

Continuation for all vehicles

-- Press the release buttons -1- and remove the vacuum line -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the subframe without the steering gear. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Remove the left and right front wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, FWD , or CATALYTIC CONVERTER, REMOVING AND INSTALLING, AWD .

-- Remove the fan shroud. Refer to Fan Shroud, Removing and Installing .

-- Remove the front air duct pipe. Refer to [For engine(s) DSFD, DSFE] Front Air Duct Pipe, Removing and Installing .

Vehicles with Parking Heater:

-- Loosen the clamp -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nut -2-.

-- Remove the muffler.

Continuation for all vehicles

Vehicles with A/C Compressor:

-- Remove the A/C compressor from the bracket. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET , or A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .

Continuation for all vehicles

-- Remove the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

Vehicles with Front Axle Differential Lock:

-- Disconnect the connector -arrow-.

Fig 3: Locating Axle Differential Lock Control Module Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for all vehicles

AWD Vehicles:

-- Remove the driveshaft from the bevel box and tie up. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

Continuation for all vehicles

Vehicles with Transmission Fluid Auxiliary Hydraulic Pump 1 -V475-

-- Disconnect the connector -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for all vehicles

Vehicles with Auxiliary Radiator:

-- Lift the clips -arrows- and remove the coolant hoses -1- and -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for all vehicles

-- Lift the clip -arrow- and remove the coolant hose -1-.

Fig 4: Identifying Upper Radiator Coolant Hose Retaining Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Vehicles without Parking Heater:

-- Lift the clip -arrows- and remove the coolant hoses.

Fig 5: Identifying Heater Core Hoses

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Continuation for all vehicles

Vehicles with Parking Heater:

-- Loosen the clamp -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Lift the clip -arrows- and remove the coolant hoses.

Continuation for all vehicles

-- Depending on the equipment/version, remove the bolt -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamps -1- and remove the charge air hose.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamp -2- and remove the charge air hose.

Fig 6: Identifying Clamps

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolt -arrow-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Push the bracket to the side.

-- Loosen the bolts -arrows- two turns.

Fig 7: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the bolts -arrows- two turns.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the Adapter :T10359/3 -B- to the Engine/Gearbox Jack - Engine Support :T10359A -A-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Guide the bolt -1- through the adapter -B- and attach the spacer sleeve -2-.

-- Tighten the Engine/Gearbox Jack - Pin :T10359/2 -D- with Transmission Support - Mounting Plate :3282/059 -C-.

-- Insert the engine bracket -A- into the Engine and Gearbox Jack :VAS 6931 -E-.

-- Position the Engine/Gearbox Jack - Engine Support :T10359A -A- on the cylinder block.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the bolt -1- with the spacer sleeve -2-.

Condition

The tightening specification of 20 Nm must be met

-- Secure the engine/transmission assembly with Transmission Support - Mounting Plate 59 :3282/059 -C- and slightly lift up.

-- Remove the bolts -arrows-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the bolts -arrows-.

Fig 8: Identifying Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION:

Risk of damaging the lines and hoses, as well as the engine compartment by lowering the engine/transmission assembly.

- Make sure all connections between the engine, transmission, subframe and body have been disconnected.

- Carefully guide the engine/transmission assembly with the subframe out of engine compartment when lowering.

-- Lower the engine/transmission assembly in -direction of the arrow 1-, at the same time pay attention to leave enough distance to other components.

Fig 9: Identifying Engine Jack

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.