Volkswagen Workshop Service and Repair Manuals

Removing engine   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 that are opened or cut through when the engine is removed must be renewed/replaced in the same position when the 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 and electrical wiring so that they are in their original positions. t  Ensure that there is sufficient clearance to all moving or hot components. –  Read event memories of all control units before removing → Vehicle diagnostic tester. –  Disconnect earth strap at battery with ignition switched off → Electrical system; Rep. gr.27. –  Remove engine cover → Chapter. –  Remove air filter → Chapter.

–  Remove battery and battery tray. –  Remove wiper arms → Electrical system; Rep. gr.92. –  Remove plenum chamber cover → General body repairs, exterior; Rep. gr.64. Golf, Eos: –  Remove bulkhead plenum chamber → Body - front; Rep. gr.50. –  Pull left engine wiring harness connector off at engine control unit → Chapter. –  If fitted, remove charge air duct to sound generator → Chapter. Passat, CC: –  Pull left engine wiring harness connector off at engine control unit → Chapter. Tiguan: –  Pull left engine wiring harness connector off at engine control unit → Chapter.

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

–  Slide the two clips in the direction of the -arrows- and remove cover from electronics box in engine compartment.

–  Unscrew cable from alternator -A- and cable from battery -B- at fuse box.

–  Unscrew earth cable from longitudinal member -arrow-.

–  Open cable duct latches on longitudinal member -arrows-.

–  Expose electrical connector -1- and separate. –  Open wiring duct bracket located below -2-. –  Remove wiring harness for engine control unit from wiring duct and place on engine. 1.8 l vehicles with manual gearbox: –  Remove selector mechanism from gearbox → Rep. gr.34.

–  Remove brace -1-. –  Remove slave cylinder -arrows- and lay to side. Do not open hydraulic system.   Caution Do not press clutch pedal after removing slave cylinder. This can damage the slave cylinder. 2.0 l vehicles with manual gearbox: –  Remove selector mechanism from gearbox → Rep. gr.34.

–  Clamp off supply hose to clutch master cylinder using hose clamp -3094-.

–  Pull clip -arrow- for pipe line out as far as stop. –  Pull pipe line out from breather/slave cylinder and seal.   Caution Do not depress clutch pedal. Vehicles with automatic gearbox: –  Remove selector lever cable from gearbox → Rep. gr.37. Vehicles with DSG®: –  Remove selector cable from gearbox → Power transmission; Rep. gr.34. Tiguan with automatic gearbox: –  Remove lines leading to gear oil cooler from gearbox → Automatic gearbox; Rep. gr.37. Continuation for all vehicles:

–  Disconnect electrical connector -2-.

–  Unscrew upper securing bolts for air ducting -arrows-.

–  Loosen hose clip -2-. –  Remove bolt -4-. –  Disconnect electrical connector -arrow- and move electrical wires clear.   WARNING When the engine is warm, the cooling system is under pressure. Hot steam/hot coolant can escape - risk of scalding. Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. –  Open filler cap on expansion tank. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front part of wheel housing liners or front wheel housing liners → General body repairs, exterior; Rep. gr.66.

–  Remove charge air hoses -arrows-.

–  Disconnect connector -1- and unscrew lower securing bolts -arrows- for air ducting. –  Remove air ducting downwards.

–  Remove bolt -1- and take out air pipe downwards.

–  Disconnect electrical connector -2- for radiator outlet coolant temperature sender -G83-.   Note Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop crane -VAS 6208- beneath engine. –  Drain coolant → Chapter.

–  Remove coolant hoses -1 and 2-.   WARNING Fuel supply line is pressurised. Wear eye protection and protective clothing to avoid possible injury and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Separate existing lines from the fuel transfer point.    1) Breather pipe    2) Vacuum line    3) Fuel supply line

Golf, Passat, CC, Eos: –  Detach coolant hose at top of radiator -arrow-. Tiguan: –  Remove coolant from radiator on right-hand side and pull coolant off radiator on left-hand side.

All: –  Remove coolant hoses to heater heat exchanger -arrows-. Pull out retaining bar slightly to do this.

–  Remove nuts (accessible from above) -arrows- securing front exhaust pipe to turbocharger.

–  Pull off vacuum hoses -arrows-.

Vehicles with front-wheel drive –  Remove heat shield for drive shaft on right side -arrows-. All: –  Remove drive shafts → Running gear, axles, steering; Rep. gr.40. –  Remove front exhaust pipe with catalytic converter → Chapter.   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen for re-installation.

–  To slacken poly V-belt turn tensioner from below in direction of -arrow-. –  Lock tensioner with locking pin -T10060 A-. –  Remove poly V-belt.

–  Disconnect electrical connector -1- for air conditioning compressor regulating valve -N280-.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Tie up air conditioner compressor together with refrigerant hoses to longitudinal member (refrigerant hoses remain connected). Golf, Eos, Scirocco: –  Remove alternator -C- → Rep. gr.27.

All: –  Remove bolt -2- at bracket for coolant pump for continued circulation -V51-.   Note The continued circulation coolant pump -V51- remains installed.

–  First, undo bolt -1- and then bolts -2…3- and remove pendulum support.

–  If fitted, unplug electrical connector -1- for oil level and oil temperature sender -G266- and unclip bracket -2- from assembly carrier. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Disconnect all connection, coolant, vacuum and intake hoses from engine. l  Screw pin -T10359/2- into engine bracket -T10359- and screw on clamping device from gearbox set.

–  Position engine bracket -T10359--1- on engine and insert in mountings. –  Close tensioning element -3- to prevent engine from tilting out of engine bracket -T10359-.

–  Attach engine bracket -T10359--1- with bolt -3- to cylinder block and tighten to approx. 20 Nm.   Note Tapped hole for bolt -1- secures continued coolant circulation pump -V51-. –  Insert engine and gearbox jack -V.A.G 1383 A- in engine bracket -T10359-. –  Lift engine together with gearbox slightly.   Note Use stepladder -VAS 5085- to undo bolts for assembly mounting.

–  Remove bolts -arrows- of assembly mounting at engine.

–  Remove bolts -arrows- of assembly mounting at gearbox.   Note t  Check that all hose and line connections between engine, gearbox and body have been detached. t  Engine with gearbox must be guided carefully when lowered to prevent damage. Dual clutch gearbox: l  Note the selector lever cable. All: –  Pull engine with gearbox as far forwards and to the left as possible, and then lower gradually. Secure engine on engine and gearbox support -VAS 6095- to carry out repairs → Chapter.