♦ Release lever - 80 - 200-
♦ Lifting tackle - 2024 A-
♦ Engine and gearbox jack - V.A.G 1383 A-
♦ Hose clip pliers - V.A.G 1921- or hose clip pliers - VAS 6362-
♦ Stepladder , commercially available
♦ Engine bung set - VAS 6122-
♦ Drip tray for workshop hoist - VAS 6208-

Rep. gr.10 - Removing and installing engine

♦ Engine bracket - T10359 A- with pin - T10359/2-

♦ Locking device from gearbox support - 3282-

Remove engine

⇒ page 5

Disconnecting gearbox from engine and assembling

⇒ page 15

Securing engine to assembly stand

⇒ page 18

Install engine

⇒ page 19

Assembly mountings

⇒ page 21

1.1

Removing engine

Note

♦

The battery earth must be disconnected for the remaining pro‐

cedure. Therefore, first check whether a coded radio is fitted.

Then obtain anti-theft coding first if necessary.

♦

The engine is removed downwards together with the gearbox.

♦

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

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:

♦ Route all the various lines and electrical wiring so that they

are in their original positions.

♦ Ensure that there is sufficient clearance to all moving or

hot components.

1. Removing and installing engine

– 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 ; Disconnecting and connecting

battery.

– Remove engine cover panel

⇒ page 141

– Remove air filter

⇒ page 467

– Remove battery and battery tray.
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing windscreen

wiper system; Removing and installing wiper arms .

– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 64 ; Flush bonded windows; Assembly over‐

view - plenum chamber cover .

Golf, Eos:
– Remove bulkhead plenum chamber ⇒ Body - front; Rep. gr.

50 ; Assembly overview - bulkhead plenum chamber .

– If fitted, remove charge air duct to sound generator

⇒ page 455

All:
– If fitted, release feed-through for engine wiring harness

-arrow- and pull off upwards.

– Pull left engine wiring harness connector off at engine control

unit.

⇒ “4 Engine control unit J623 (Passat, CC up to 11/10)”, page

499
⇒ “5 Engine control unit J623 (Golf, Eos to 11/08)”,

page 502
⇒ “6 Engine control unit J623 (Golf, Eos, Scirocco from 11/08;

CC from 11/10)”, page 506
⇒ “7 Engine control unit J623 (Tiguan)”, page 511
⇒ “8 Engine control unit J623 (Scirocco to 11/08)”,

page 514

– Slide the two clips in the direction of the -arrows- and remove

cover from electronics box in engine compartment.

Rep. gr.10 - Removing and installing engine

– 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 guide 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 ;

Removing and installing selector mechanism .

1. Removing and installing engine

– Remove brace -1-.
– Detach slave cylinder -arrows- and place to one side. Do not

open pipes.

Caution

Do not press clutch pedal after removing slave cylinder. This

can damage slave cylinder.

2.0 l vehicles with manual gearbox:
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;

Removing and installing selector mechanism .

– Clamp off supply hose to master cylinder using hose clamp -

3094- .

– Pull out clip -arrow- for pipe line to stop.
– Pull pipe line out from slave cylinder bleeder and seal it.

Caution

Do not depress clutch pedal any longer.

Vehicles with automatic gearbox:
– Remove selector lever cable from gearbox ⇒ Rep. gr. 37 ;

Removing and installing gear change mechanism .

Vehicles with DSG®:
– Remove selector cable from gearbox ⇒ Power transmission;

Rep. gr. 34 ; Selector mechanism; Removing and installing

selector lever cable .

Tiguan with automatic gearbox:
– Remove lines leading to gear oil cooler from gearbox ⇒ Au‐

tomatic gearbox; Rep. gr. 37 .

Continued for all vehicles:

Rep. gr.10 - Removing and installing engine

– Disconnect electrical connector -2-.

– Unscrew upper securing bolts for cowling -arrows-.

– Release hose clip -2-.
– Unscrew bolt -4-.
– Disconnect electrical connector -arrow- and move electrical

wires clear.

WARNING

The cooling system is under pressure when the engine is hot!
Danger of scalding by steam and hot coolant.
Cover filler cap on expansion tank with a cloth and open care‐

fully to release pressure.

– Open filler cap on expansion tank.
– Remove noise insulation ⇒ General body repairs, exterior;

Rep. gr. 50 ; Assembly overview - noise insulation; noise in‐

sulation .

– Remove front part of wheel housing liners or front wheel hous‐

ing liners ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel

housing liner .

1. Removing and installing engine

– Remove charge air hoses -arrows-.

– Detach connector -1- and unscrew lower securing bolts

-arrows- for cowling.

– Remove cowling downwards.

– Cover radiator using protective mat - VAS 531 003- .

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

Rep. gr.10 - Removing and installing engine

– Separate electrical connector -2- for radiator outlet coolant

temperature sender - G83- .

– Place drip tray - VAS 6208- beneath engine.
– Drain coolant

⇒ page 241

– Remove coolant hoses -1 and 2-.

WARNING

Fuel supply line is pressurised. Wear protective goggles and

protective clothing to avoid injury and contact with the skin.

Wrap a cloth around the connection before loosening hose

connections. Then release pressure by carefully pulling hose

off connection.

– Separate existing lines from the fuel transfer point.

1) Breather hose
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 cool‐

ant off radiator on left-hand side.

1. Removing and installing engine

All:
– Remove coolant hoses to heater heat exchanger -arrows-.

Pull out locking 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 ; Removing and installing drive shafts .

– Remove front exhaust pipe with catalytic converter:

Passat CC

Golf, Eos, Scirocco

Caution

Danger of destruction due to reverse running direction in the

case of a poly V-belt that has already run.

♦ Before removing the poly V-belt, use a piece of chalk or a

felt pen to mark the running direction.

Rep. gr.10 - Removing and installing engine

– Turn tensioner in direction of -arrow- to relieve tension on poly

V-belt.

– Use the locking pin - T10060 A- to lock the tensioner.
– Remove poly V-belt.

– Remove electrical connector -1- for control valve for compres‐

sor of air-conditioning system - N280- .

WARNING

Danger of injury due to coolant.

♦ Do not open the air conditioner refrigerant circuit.

– Unscrew bolts -arrows- for air conditioning compressor.

Caution

Danger of damage to coolant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.

– Fasten air-conditioning compressor together with connected

coolant hoses to the longitudinal member above.

Golf, Eos, Scirocco:
– Removing radiator

⇒ page 275

– Remove alternator - C- ⇒ Rep. gr. 27 .

All:
– Remove bolt -2- at bracket for coolant pump for continued cir‐

culation - V51- .

Note

The continued circulation coolant pump - V51- remains installed.

1. Removing and installing engine

– First, undo bolt -1- and then bolts -2…3- and remove pendu‐

lum support.

– If fitted, unplug electrical connector -1- for oil level and oil tem‐

perature sender - G266- and unclip bracket -2- from subframe.

– Pull off or disconnect all other electrical connections from the

engine and gearbox as necessary and lay open.

– Disconnect all connection, coolant, vacuum and intake hoses

from engine.

Caution

Always use the pin - T10359/2- and the securing element from

gearbox support - 3282- . Otherwise the engine can tip.

• Screw pin - T10359- into engine support - T10359/2- and

screw on safety support from gearbox support - 3282- -A-.

– Position engine bracket -T10359- -1- on engine and insert in

mountings.

– Close safety support -3- to prevent engine from tilting out of

engine support -T10359- .

Rep. gr.10 - Removing and installing engine

– Attach engine support -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 sup‐

port -T10359- .

– Lift engine together with gearbox slightly.

Note

Use a stepladder - VAS 5085- to unscrew the bolts for the as‐

sembly mountings.

– Unscrew bolts -arrows- of engine/gearbox support on the en‐

gine.

– Unscrew bolts -arrows- of engine/gearbox support on gear‐

box.

Note

♦

Check that all hose and line connections between engine,

gearbox and body have been detached.

♦

Engine with gearbox must be guided carefully when lowered

to prevent damage.

Dual clutch gearbox:
• 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

⇒ page 18

1.2

Separating gearbox from engine and assembling

1. Removing and installing engine

Special tools and workshop

equipment required

♦ Shackle - 10 - 222 A /12-
♦ Workshop hoist - VAS 6100-
♦ Vehicles with automatic gearbox: insert tool AF 18 - T10179-
♦ Vehicles with automatic gearbox: insert tool - V/175-
♦ Vehicles with automatic gearbox: special wrench - T10035-
Separate gearbox from engine:
Conditions
• Engine with gearbox removed and secured on engine bracket

- T10359- .

– Remove starter ⇒ Rep. gr. 27 ; Removing and installing start‐

er .

Automatic gearbox and DSG®
– Remove coolant hoses (if any) from gearbox oil cooler and

seal apertures.

Vehicles with all-wheel drive
– Remove bevel box (automatic gearbox) ⇒ Gearbox; Rep. gr.

39 .

Rep. gr.10 - Removing and installing engine

– Remove bevel box (manual gearbox) ⇒ Gearbox; Rep. gr.

34 .

All
– Disconnect all electrical connections from gearbox to engine

and move them to one side.

– Secure gearbox to workshop hoist with shackle - 10 - 222 A /

12- , but do not raise.

– Remove upper engine/gearbox securing bolts.
Manual gearbox and DSG®
– Before now removing final securing bolts, support gearbox

with workshop hoist.

– Remove lower engine/gearbox connecting bolts.
– Press gearbox off from engine, guiding the gearbox
Automatic gearbox
Bolts can be loosened with bit - T10179- . When tightening, how‐

ever, note the lower tightening torque ⇒ 6-speed automatic

gearbox 09G; Rep. gr. 37 ; Removing and installing gearbox .
Socket - T10035- simplifies the work.
– Leave an easily accessible bolt in for safety purposes.
– Start with the two lower bolts.
The hole for removing the torque converter nut is covered with a

rubber cap on the rear of the engine.
– Remove this cap.

– Remove 6 converter nuts -arrow- using insert tool - V/175- .

Note

♦

Continue turning the engine carefully!

♦

When installing, take special care to turn the engine carefully

»while guiding the gearbox onto the engine«. The starter ring

gear can be held from the outside with a screwdriver. The

studs will then engage in the holes in the drive plate.

– Before now removing the final connecting bolt, support gear‐

box with workshop hoist.

– Only now is the final bolt removed.
– Press gearbox off from engine, guiding the gearbox

Note

Observe torque converter. It must be removed together with gear‐

box.

1. Removing and installing engine

– During transportation, protect torque converter -arrow- from

falling out, e.g. with a wire -A-.

Installing
Assembly is carried out in the reverse order; in this case, note the

specified torques in the relevant gearbox workshop manuals un‐

der »Removing and installing gearbox«.

1.3

Securing engine to assembly stand

Special tools and workshop

equipment required

♦ Lifting tackle - 2024 A-

Rep. gr.10 - Removing and installing engine

♦ Workshop hoist - VAS 6100-
♦ Engine and gearbox support - VAS 6095-
Conditions
• Engine with gearbox removed and secured on engine bracket

- T10359- .

– Separate gearbox from engine

⇒ page 15

– Attach lifting tackle - 2024 A- as shown and lift from engine

and gearbox jack - VAS 6100- using workshop crane - V.A.G

1383 A- .

Caution

Use securing pins arrows on hooks and locking pins to avoid

damage to engine.

– Secure engine to engine and gearbox support - VAS 6095- .

1.4

Installing engine

Assembly mountings

⇒ page 21

Installation is carried out in the reverse order. When installing,

note the following:

Caution

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:

♦ Route all the various lines and electrical wiring so that they

are in their original positions.

♦ Ensure that there is sufficient clearance to all moving or

hot components.

– Check dowel sleeves for centring engine/gearbox and renew

if damaged.

1. Removing and installing engine

– Hook intermediate plate onto sealing flange and slide onto

dowel sleeves -arrows-.

Vehicles with manual gearbox:
– Lightly grease input shaft splines with grease - G 000 100- .
– Check clutch and clutch actuation mechanism and install ⇒

Manual gearbox; Rep. gr. 30 ; Repairing clutch actuation

mechanism .

Vehicles with DSG®:
– Renewing needle bearing in crankshaft

⇒ page 75

– Adjust selector lever cable following installation ⇒ Power

transmission; Rep. gr. 34 ; Selector mechanism; Adjusting

selector lever cable .

Continued for all vehicles:
– When installing the engine and gearbox assembly, make sure

there is sufficient clearance to the subframe and radiator.

– Adjusting assembly mountings - Passat, CC

⇒ page 24

– Adjust assembly mounting - Golf

⇒ page 28

– Adjust assembly mounting - Tiguan

⇒ page 32

Note

Specified torques for assembly mountings

⇒ page 21

Electrical connections and routing ⇒ Electrical system; Rep. gr.

97 .
– Connect vehicle diagnostic tester .
– Read all event memories and clear any event entries that have

been created during assembly.

– Perform road test.
– Then carry out the vehicle system test again and correct any

faults that have been created.

Note

If the event memory was cleared, the readiness code must be

generated ⇒ Vehicle diagnostic tester “Guided Functions”.

Specified torques:

Bolted connection

Specified torque

Nuts and bolts

10 Nm

15 Nm

25 Nm

M10

40 Nm

M12

60 Nm

Rep. gr.10 - Removing and installing engine

Assembly mountings

⇒ “2.1 Assembly overview - assembly mountings (Golf, Eos, Pas‐

sat, CC, Scirocco)”, page 21

⇒ “2.2 Assembly overview - assembly mountings (Tiguan)”, page

⇒ “2.3 Checking adjustment of assembly mountings (engine and

gearbox mountings)”, page 24

⇒ “2.4 Adjusting assembly mountings (Passat 2006 ▶, CC)”, page

⇒ “2.5 Adjusting assembly mountings (Golf, Eos, Scirocco)”, page

⇒ “2.6 Adjusting assembly mounting (Tiguan)”, page 32

2.1

Assembly overview - assembly mountings (Golf, Eos, Passat, CC, Sciroc‐

co)

1 - Bolt

❑ Gearbox support to

gearbox

❑ Specified torque ⇒ Rep.

gr. 34

2 - Bolts

❑ Pendulum support to

gearbox

❑ Torque setting ⇒ Run‐

ning gear, axles, steer‐

ing; Rep. gr. 40 ; As‐

sembly overview - Sub‐

frame, anti-roll bar, sus‐

pension links

3 - Engine support
4 - Bolt

❑ Engine support to en‐

gine

❑ Renew
❑ 40 Nm + 180° (

/2 turn

further)

5 - Engine mounting
6 - Bolt

❑ Engine mounting to

body

❑ Renew
❑ 40 Nm + 90° (

/4 turn

further)

7 - Support
8 - Bolt

❑ Support at engine

mounting

❑ Renew
❑ 20 Nm + 90° (

/4 turn further)

2. Assembly mountings

9 - Bolt

❑ Support to body
❑ Renew
❑ 20 Nm + 90° (

/4 turn further)

10 - Bolt

❑ Engine mounting to body
❑ Renew
❑ 40 Nm + 90° (

/4 turn further)

11 - Bolts

❑ Engine mounting to engine support
❑ Renew
❑ 60 Nm + 90° (

/4 turn further)

12 - Pendulum support
13 - Bolt

❑ Pendulum support to subframe
❑ Bolt pendulum support to gearbox and then to subframe.
❑ Renew
❑ 100 Nm + 90° (

/4 turn further)

14 - Bolt

❑ Gearbox mounting to gearbox support
❑ Renew
❑ 60 Nm + 90° (1/4 turn) further

15 - Bolt

❑ Gearbox mounting to body
❑ Renew
❑ 40 Nm + 90° (1/4 turn) further

16 - Gearbox mounting

❑ Illustration shows version for dual clutch gearbox.

17 - Bolt

❑ Gearbox support to gearbox
❑ Specified torque ⇒ Rep. gr. 34

18 - Rear final drive support

Rep. gr.10 - Removing and installing engine

2.2

Assembly overview - assembly mountings (Tiguan)

1 - Bolt

❑ Renew
❑ 20 Nm + 90° (

/4 turn)

further

2 - Bolt

❑ Engine mounting to

body

❑ Renew
❑ 40 Nm + 90° (

/4 turn

further)

3 - Engine mounting
4 - Bolt

❑ Engine mounting to

body

❑ Renew
❑ 40 Nm + 90° (

/4 turn

further)

5 - Bolts

❑ Engine mounting to en‐

gine support

❑ Renew
❑ 60 Nm + 90° (

/4 turn

further)

6 - Pendulum support
7 - Bolt

❑ Pendulum support to

subframe

❑ Bolt pendulum support

to gearbox and then to

subframe.

❑ Renew
❑ 100 Nm + 90° (

/4 turn further)

8 - Bolt

❑ Pendulum support to gearbox
❑ Torque setting ⇒ Running gear, axles, steering; Rep. gr. 40 ; Assembly overview - Subframe, anti-roll

bar, suspension links

9 - Bolt

❑ Pendulum support to gearbox
❑ Torque setting ⇒ Running gear, axles, steering; Rep. gr. 40 ; Assembly overview - Subframe, anti-roll

bar, suspension links

10 - Bolts

❑ Gearbox mounting to gearbox
❑ Renew
❑ 60 Nm + 90° (1/4 turn) further

11 - Bolts

❑ Gearbox mounting to body
❑ Renew

2. Assembly mountings

❑ 40 Nm + 90° (1/4 turn) further

12 - Gearbox mounting

❑ Illustration shows version for dual clutch gearbox.

13 - Engine support
14 - Bolts

❑ Engine support to engine
❑ Renew
❑ 40 Nm + 180° (

/2 turn further)

2.3

Checking adjustment of assembly

mountings (engine and gearbox mount‐

ings)

There must be a distance -a- of at least 10 mm between engine

support and longitudinal member (right side).
The side surface of the engine support -2- should be located par‐

allel to the support arm -1-.
– If the conditions are not met, the assembly mountings must be

adjusted

⇒ page 21

2.4

Adjusting assembly mountings (Passat

2006 ▶, CC)

Note

If just the assembly mounting on the engine side is to be adjusted,

one hook - 10 - 222 A /10- will suffice on the engine side. There

is also no need to remove air filter, battery and battery carrier.

Rep. gr.10 - Removing and installing engine

Content .. 1 2 ..

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