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