Volkswagen Workshop Service and Repair Manuals

Removing engine Securing engine to assembly stand → Chapter.   Note t  Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary. t  The engine is removed downwards together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.   Caution When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27. –  Remove engine cover/air filter → Chapter.

–  Remove battery and battery tray. Golf, Eos: –  Remove wiper arms, plenum chamber cover and plenum chamber bulkhead → Electrical system; Rep. gr.92. –  Pull engine wiring harness connector off engine control unit.

–  Release feed-through for engine wiring harness -arrow- and pull off upwards. Passat: –  Remove wiper arms and plenum chamber cover → Rep. gr.92. –  Pull engine wiring harness connector off engine control unit.

–  Release feed-through for engine wiring harness -arrow- and pull off upwards. All vehicles:

–  Unscrew cable from alternator at fuse holder -arrow-.

–  Unscrew earth cable from longitudinal member -arrow-.

–  Open wiring guide catches on longitudinal member -arrows-. –  Separate all connectors between engine wiring harness and body and lay engine wiring harness on engine. Engine code BPY:   WARNING The fuel system is pressurised! t  Wear eye protection and protective clothing to avoid possible injury and skin contact. t  Before loosening line connections, wrap a cloth around the connection. Then release pressure by carefully pulling off line.

–  Disconnect lines -1, 2 and 3-. Do this by operating release buttons. Engine codes AXX, BWA   WARNING The fuel system is pressurised! t  Wear eye protection and protective clothing to avoid possible injury and skin contact. t  Before loosening line connections, wrap a cloth around the connection. Then release pressure by carefully pulling off line.

–  Disconnect breather line -1- and fuel supply line -2-. Golf, Eos:

–  Disconnect breather line -2-. Pull activated charcoal filter with hoses upwards out of bracket. Continuation for all vehicles: –  Remove noise insulation → General body repairs, exterior; Rep. gr.50.

–  Remove left and right wheel housing liner front part.

–  Remove charge air hoses -arrows-.

–  Unbolt heat shield for right-hand drive shaft -arrows-. –  Remove left and right drive shafts → Running gear, axles, steering; Rep. gr.40. –  Remove front exhaust pipe with catalytic converter → Chapter. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. –  Drain coolant → Chapter. –  Empty air conditioning → Rep. gr.87.

–  Disconnect air conditioning line -arrow- from air conditioner compressor.

–  Remove air conditioner line from condenser -arrow-.

–  Unscrew bolts -1…3- and remove pendulum support. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox: –  Remove selector mechanism from gearbox → Rep. gr.34.

–  Clamp-off hose for pipe/hose line -A- to slave cylinder using hose clips -3094-. –  Pull clip -arrow- for pipe/hose line out as far as stop. –  Pull pipe/hose line out of slave cylinder breather.   Caution Do not depress clutch pedal. Vehicles with automatic gearbox: –  Disconnect selector lever cable from gearbox → Automatic gearbox 09G; Rep. gr.37. Vehicles with DSG®: –  Remove selector lever cable from gearbox: → Power transmission; Rep. gr.34. Continuation for all vehicles:

–  Unscrew coolant circulation pump -V50--arrows-. –  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.

–  Place engine bracket -T10012- on engine as shown and tighten bolt -1- and nut -2- to approx. 20 Nm. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.

–  Unscrew assembly mounting on engine side from engine bracket -arrows-.

–  Unscrew assembly mounting on gearbox side from gearbox support -arrows-.   Note t  To remove securing bolts use a stepladder -VAS 5085-. t  Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork. –  Carefully lower engine with gearbox.