Volkswagen Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Engine support -T40075- with adapters /1, /2, /3

t	Torque wrench (5…50 Nm) -V.A.G 1331-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Engine and gearbox support -VAS 6095-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t	Stepladder -VAS 5085-

t	Torque wrench (40…200 Nm) -V.A.G. 1332-

t	Guide rods -T10093-

Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.

–  Remove securing bolts -1- from engine cover panel. –  Detach coolant hoses -2- at engine cover panel and pull engine cover panel upwards. –  Remove air filter → Chapter. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter. –  Observe rules for cleanliness → Chapter. –  Separate fuel supply line -1- and line to activated charcoal filter -2-. –  Separate push-on couplings → Chapter.   WARNING Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. Golf, Golf Plus, Eos, Scirocco

–  Remove hose -3- from activated charcoal filter system solenoid valve 1 -N80- to activated charcoal filter. –  Pull activated charcoal filter upwards and remove securing bolts -arrows- from bracket. Continuation for all vehicles –  Remove coolant hoses -4-.

–  Release coolant hoses -1- and -2- at radiator and pull them off.

–  Release coolant hoses at heat exchanger -arrows- and pull them off.

–  Unscrew securing bolts -arrows- and remove heat shield from turbocharger.

–  Unbolt securing nuts at turbocharger -arrows-.

–  Remove securing bolts -arrows- of engine splash protection. –  Remove front left and right wheel housing liners → General body repairs; Rep. gr.66.

–  Release coolant hose -1- at auxiliary radiator for charge air system and remove coolant pipe -2-.

–  Pull connector -1- off oil level and oil temperature sender -G266-. –  If an auxiliary heater is fitted, remove coolant pipes -2-. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. –  Unclip wiring -1- from catalytic converter.

–  Disconnect connectors -2-. –  Unscrew securing nuts -3- and remove seal. –  Remove catalytic converter downwards.

–  Unbolt exhaust pipe together with decoupling element -arrows-.

–  Loosen securing bolts of double clamp -arrows- and pull exhaust pipe to rear. The engine is removed downwards together with the gearbox. –  Disconnect battery → Electrical system; Rep. gr.27. –  Remove battery and battery tray → Electrical system; Rep. gr.27. –  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. –  Disconnect all electrical wiring from gearbox, alternator and starter and lay to side. –  Pull off or disconnect all other electrical connections as necessary from engine and lay to side. –  Pull vacuum and breather hoses off engine. –  Pull connectors off thermal switch and radiator fan. –  Remove plenum chamber bulkhead → General body repairs; Rep. gr.50. –  Remove engine control unit → Chapter.

–  Open all line guide fasteners -arrows-. –  Remove wiring from engine control unit. –  Secure lines/wiring to engine with a cable tie.

–  Disconnect pendulum support -arrows-. Vehicles with manual gearbox –  Unbolt selector mechanism from gearbox → 6-speed manual gearbox 02S; Rep. gr.34. –  Remove hydraulic clutch slave cylinder: → 6-speed manual gearbox 02S; Rep. gr.30   Note Clutch pedal must not be depressed. –  Remove right drive shaft, and unscrew left drive shaft from gearbox and tie up: → Running gear, axles, steering; Rep. gr.40. Vehicles with automatic gearbox –  Remove selector lever cable → 7-speed dual clutch gearbox 0AM; Rep. gr.34. –  Removing both drive shafts → Running gear, axles, steering; Rep. gr.40. Continuation for all vehicles –  Disconnect connector -1- from coolant circulation pump -V50-.

–  Detach spring-type clips -2- and pull coolant hoses off. –  Unscrew securing bolt -3- and remove pump from bracket.

–  Remove bracket for coolant circulation pump -V50- from crankcase -arrows-. –  Remove poly V-belt → Chapter. –  Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87   Note The air conditioning system lines must not be opened. –  Secure air conditioner compressor to lock carrier. –  Ensure that lines are not kinked. –  Observe additional information and installation work → Chapter.

Engine support -T40075- with adapters -/1-, -/2- and -/3- is required to to lower engine with gearbox.

–  Screw adapter -T40075/1- to stop into crankcase. –  Position the engine support -T40075- with adapters -/2- and -/3- on crankcase. –  Insert two M10 nuts between crankcase and engine support -T40075-.

–  Secure engine support -T40075- hand-tight to crankcase using an M8x35 bolt -1-.

–  Tighten all bolts on engine support -T40075- to 20 Nm. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.

–  Unbolt engine side of assembly mounting from above -arrows-.

–  Unbolt gearbox side of assembly mounting from above -arrows-.   Note To remove securing bolts use a stepladder -VAS 5085-. –  Carefully lower engine and gearbox.