Volkswagen Golf Variant / Jetta. Manual - part 355

 

  Index      Volkswagen     Volkswagen Golf Variant (2007), Jetta (2005) - service repair manual

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  353  354  355  356   ..

 

 

Volkswagen Golf Variant / Jetta. Manual - part 355

 

 

1

Engine, Removing and Installing

⇒ “1.1 Engine, Removing”, page 3
⇒ “1.2 Transmission and Engine, Disconnecting and Assem‐

bling”, page 12
⇒ “1.3 Engine, Securing to Engine and Gearbox Bracket

VAS6095A ”, page 13
⇒ “1.4 General Installation Information”, page 14

1.1

Engine, Removing

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Special tools and workshop equipment required
♦ Lifting Tackle - 3033-
♦ Hose Clamps - Up To 25mm - 3094- (vehicles with manual

transmission)

♦ Torque Wrench 1331 5-50Nm - VAG1331-
♦ Torque Wrench 1332 40-200Nm - VAG1332-
♦ Step Ladder - VAS5085-
♦ Shop Crane - VAS6100-
♦ Shop Crane - Drip Tray - VAS6208-
♦ Hose Clip Pliers - VAS6362-
♦ Transportation Lock - T10404-
♦ Engine Bung Set - VAS6122- (not illustrated)

DANGER!

♦ Follow the safety precautions when working on the diesel

direct fuel injection system. Refer to

⇒ “1 Safety Precautions when Working on Diesel Direct

Fuel Injection System”, page 303

 .

♦ Pay attention to the guidelines for clean working condi‐

tions. Refer to

⇒ “2 Guidelines for Clean Working Conditions”,

page 305

 .

Always pay attention to these instructions before and during

work.

1. Engine, Removing and Installing    

3

Subframe mount. Refer to

⇒ “2 Subframe Mount, except Jetta from MY 2011”,

page 17

 .

Overview - Body Side Cooling System Components. Refer to

⇒ “1.1 Overview - Cooling System Components, Body Side”,

page 190

 .

Overview - Fuel Filter. Refer to

⇒ “6.2 Overview - Fuel Filter”, page 249

 .

Overview - Turbocharger with Exhaust Manifold and Attach‐

ments. Refer to

⇒ “3.1 Overview - Turbocharger with Exhaust Manifold and

Attachments”, page 270

 .

Overview - Charge Air Cooler Components. Refer to

⇒ “4.2 Overview - Charge Air Cooler Components”,

page 290

Overview - Particulate Filter with NOx Reduction Catalytic

Converter. Refer to

⇒ “1.2 Overview - Particulate Filter with NOx Reduction Cat‐

alytic Converter”, page 360

 .

Overview - EGR Components. Refer to

⇒ “3.1 Overview - Exhaust Gas Recirculation System Com‐

ponents”, page 398

 .

Hose connections are secured with either spring or hose

clamps.

Always replace clamp-type clips with spring-type clips.

Hose Clip Pliers - VAS6362- or the Hose Clip Pliers -

VAS6340- are recommended for installing spring clips.

The Battery - A- ground cable must be disconnected for the

following procedure. For this reason check if a coded radio is

installed. If necessary, obtain anti-theft code beforehand.

All cable ties which are opened or cut open when removing

engine, must be replaced in the same position when installing

engine.

The engine is removed forward together with the transmission.

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Requirements
• Ignition switched off.
• Engine must be cold.

4

al. Refer to Vehicle Diagnostic Tester “Vehicle Self-Diagno‐

sis”.

– Remove the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

– Remove the air filter housing. Refer to

⇒ “3.14 Overview - Air Filter”, page 335

 .

– Remove the intake hose between the Mass Airflow Sensor -

G70- and the intake scoop. Loosen the spring clamps using

the Hose Clip Pliers - VAS6362- .

Caution

Electronic components could be destroyed when the Battery -

A- is disconnected:

♦ Complete the steps for disconnecting the Battery - A- .

– When the ignition is switched off, disconnect the ground cable

-arrow- from the Battery - A- . Refer to ⇒  Electrical Equipment;

Rep. Gr.  27 ; Battery; Battery, Disconnecting and Connecting .

– Remove the Battery - A- and the battery tray -arrows-.
– Disconnect on the Engine Control Module - J623- :
♦ Refer to 

⇒ “4 Engine Control Module”, page 343

 .

1. Engine, Removing and Installing    

5

direction of -arrow- and pull it off upward.

– Remove the E-box cover from the engine compartment by

sliding both latches in the direction of -arrows-.

– Disconnect the wire from the Generator - C- -A- and the wire

from the Battery - A- -B- at the fuse panel.

– Open all the cable guide locking mechanisms on the longitu‐

dinal member -arrows-.

6

 

 

 

 

 

 

 

Content   ..  353  354  355  356   ..