CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
♦ Engine bracket - T10359 A- with pin - T10359/2-
♦ Locking device from gearbox support - 3282-
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
5
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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.
6
Rep. gr.10 - Removing and installing engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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
7
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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:
8
Rep. gr.10 - Removing and installing engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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
9
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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.
10
Rep. gr.10 - Removing and installing engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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
11
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
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 ⇒ page 526
Golf, Eos, Scirocco ⇒ page 542
Tiguan ⇒ page 552
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.
12
Rep. gr.10 - Removing and installing engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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
13
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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- .
14
Rep. gr.10 - Removing and installing engine
CC 2010 ➤ , Eos 2006 ➤ , Golf 2004 ➤ , Golf 2009 ➤ , Passat 2006 ➤ , ...
4-cyl. injection engine (1.8 and 2.0 l engine, chain drive) - Edition 08.2018
– 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
15
2024 VW Passat Owner's Manual
VW Passat B7 Service & Repair Manual
VW Passat B6 Service & Repair Manual
