2011 cc the information in this article comes from a ......2/7/2018 engine, removing → removal and...

2/7/2018 Engine, Removing → Removal and Installation → Engine Mechanical Fuel Injection and Ignition • 2011 Volkswagen CC • MotoLogic

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2011 CC

Report a problem with this articleThe information in this article comes from a service manual containing information thatapplies to the following engine codes: CBFA, CCTA and the following transmission codes:02E, 02Q, 09G, 09M, 0A6.Section Info:

Engine Assembly4 Removal and Installation4.1 Engine, Removing

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Special tools and workshop equipment required

♦ Pry Lever - Rmv Outside Mirror -80-200-

♦ Engine Sling -2024 A-

♦ Engine-/Gearbox Jack -V.A.G 1383 A-

♦ Hose Clip Pliers -V.A.G 1921-

♦ Step Ladder -VAS 5085-

♦ Drip Tray for VAS 6100 -VAS 6208-

♦ Engine Support -T10359-

♦ Hose Clip Pliers -VAS 6362-

♦ Engine Bung Set -VAS 6122-

♦ Pins -T10359/2-

♦ Transmission Support -3282-

Note

♦ To perform this procedure, the ground cable must be discon‐nected from the battery. See if a coded radio is installed. If so,obtain the anti-theft code beforehand.

♦ The engine is removed downward together with the transmis‐sion.

♦ All cable ties which are opened or cut off when removing theengine, must be replaced in the same position when installingthe engine.

Caution

When doing any repair work, especially in the engine compart‐ment, pay attention to the following due to clearance issues:♦ Route all lines and wires in their original locations.♦ Ensure sufficient clearance to all moving or hot compo‐

nents.

– Check the Diagnostic Trouble Code (DTC) memories of allcontrol modules before removing the engine. Refer to the ve‐hicle diagnostic tester.

– Disconnect the battery Ground (GND) cable with the ignitionturned off. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ;Removal and Installation .



– Remove the engine cover. Refer to⇒ “4.1 Engine Cover“, page 113 .

– Remove the air filter housing. Refer to⇒ “5.1 Air Filter Housing“, page 451 .

– Remove the battery, the battery tray bolts -arrows- and tray.

– Remove the wiper arms. Refer to ⇒ Electrical Equipment;Rep. Gr. 92 ; Removal and Installation .

– Remove the plenum chamber cover. Refer to one of the fol‐lowing:

GTI (2008 through 2009), refer to ⇒ Body Exterior; Rep. Gr.64 ; Description and Operation .

Passat, refer to “Flush Bonded Windows“ in ⇒ Body Exterior;Rep. Gr. 64 ; Description and Operation

Tiguan, refer to “Moldings and Trim“ in ⇒ Body Exterior; Rep.Gr. 66 ; Description and Operation .

CC, refer to ⇒ Body Exterior; Rep. Gr. 50 ; Removal andInstallation .

Eos and GTI (from 2010), refer to ⇒ Body Exterior; Rep. Gr.50 ; Description and Operation .

GTI and Eos

– Remove the plenum chamber bulkhead. Refer to ⇒ Body Ex‐terior; Rep. Gr. 50 ; Description and Operation .

– Disconnect the engine wiring harness connector from the En‐gine Control Module (ECM). Refer to one of the following:

⇒ “5.11 Engine Control Module J623, GTI (2008 through 2009)and Eos through 11.08“, page 472 .

⇒ “5.12 Engine Control Module J623, GTI (from MY 2010) Eosfrom 11.08 and CC from 11.10“, page 475 .

– Remove the charge air pipe from the noise generator, if equip‐ped. Refer to⇒ “5.5 Charge Air Hose to Noise Generator“, page 420 .

Passat and CC

– Disconnect the engine wiring harness connector from theECM. Refer to one of the following:

⇒ “5.10 Engine Control Module J623, Passat and CC through11.10“, page 469

⇒ “5.12 Engine Control Module J623, GTI (from MY 2010) Eosfrom 11.08 and CC from 11.10“, page 475

Tiguan

– Disconnect the engine wiring harness connector from theECM. Refer to⇒ “5.13 Engine Control Module J623“, page 480 .

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Continuation for All

– Release the pass through for the engine wiring harness-arrow- and pull off upward.

– Remove the E-box cover by sliding both latches in the-direction of the arrows-.

– Remove the nut -A-, the cable from the generator and the ca‐ble from the battery -B- from the fuse holder.

– Remove the bolt -arrow- and ground wire from the longitudinalmember.



– Open the wire guide locking mechanisms -arrows- on the lon‐gitudinal member.

– Free up the electrical connector -1- and disconnect.

– Open the underlying wiring guide bracket -2-.

– Take the ECM wiring harness out of the wiring router and layit on the engine.

with a Manual Transmission

– Remove the shift mechanism from the transmission. Refer to⇒ Manual Transmission; Rep. Gr. 34 ; Removal and Instal‐lation .

– Clamp off the hose leading to the master cylinder using thehose clamp up to 25 mm dia. -3094- .



– Pull out the clip -arrow- for the hose/line assembly.

– Pull the hose/line assembly out of the slave cylinder and sealit off.

Caution

Do not press the clutch pedal.

with a Automatic Transmission

– Remove the selector lever cable from the transmission. Referto ⇒ Automatic Transmission; Rep. Gr. 37 ; Removal andInstallation .

with a Direct Shift Gearbox (DSG®)

– Remove the selector lever cable from the transmission. referto ⇒ Direct Shift Gearbox; Rep. Gr. 34 ; Removal and Instal‐lation .

Tiguan, with a Automatic Transmission

– Remove the transmission oil cooler lines from the transmis‐sion. Refer to ⇒ Automatic Transmission; Rep. Gr. 37 ;Removal and Installation .


– Disconnect the connector -2-.

– Remove the fan shroud upper bolts -upper arrows-.



– Loosen the hose clamp -2-.

– Remove the bolt -4-.

– Disconnect the connector -arrow- and free up the electricalwire.

WARNING

The coolant system is under pressure when the engine iswarm.Risk of scalding due to hot steam and hot coolant.Reduce pressure by covering the coolant expansion tank capwith a cloth and open carefully.

– Open the coolant expansion tank cap.

– Remove the noise insulation. Refer to one of the following:

GTI and Tiguan, refer to ⇒ Body Exterior; Rep. Gr. 50 ; De‐scription and Operation

Eos and Passat, refer to “Noise Insulation“ in ⇒ Body Exterior;Rep. Gr. 50 ; Removal and Installation .

CC, refer to “Noise Insulation“ in ⇒ Body Exterior; Rep. Gr.66 ; Description and Operation

– Remove the front part of the wheel housing liner or the entirefront wheel housing liner. Refer to ⇒ Body Exterior; Rep. Gr.66 ; Wheel Housing Liner .

– Remove the charge air hoses -arrows-.

– Disconnect the connector -1- and remove the fan shroud lowerbolts -lower arrows- .

– Remove the fan shroud downward.



– Remove the bolt -1- and remove the charge air pipe down‐ward.

– Disconnect the connector -2- from the engine coolant temper‐ature sensor on radiator outlet.

– Place the drip tray for VAS 6100 -VAS 6208- under the engine.

– Drain the coolant. Refer to⇒ “1.1 Coolant, Draining and Filling“, page 235 .

– Remove the coolant hoses -1 and 2-.

WARNING

The fuel supply line is under pressure. Always wear protectiveeyewear and protective clothing to prevent injuries and fuelfrom coming in contact with your skin. Wrap a cloth around theconnection before removing a fuel hose. Remove the hoseconnection carefully to release the pressure.

– Disconnect the lines at the bracket.

1 - Vent line

2 - Vacuum line

3 - Fuel supply line

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GTI, Passat, CC and Eos

– Remove the upper coolant hose -arrow- from the radiator.

Tiguan

– Remove the right coolant hose from the radiator and discon‐nect the left coolant hose from the radiator.


– Remove the bracket slightly in order to remove the heater corehoses -arrows-.

– From above, remove the front exhaust pipe to turbocharger/exhaust manifold nuts -arrows-.

– Disconnect the vacuum hoses -arrows-.



with Front Wheel Drive (FWD)

– Remove the right drive axle heat shield bolts -arrows- andshield.


– Remove the drive axles. Refer to ⇒ Suspension, Wheels,Steering; Rep. Gr. 40 ; Removal and Installation .

– Remove the front pipe with the catalytic converter. Refer to⇒ “4.5 Front Exhaust Pipe with Catalytic Converter“,page 507 .

Caution

Risk of destroying due to a reversed running direction of a usedribbed belt.♦ Before removing the ribbed belt, mark the running direc‐

tion with chalk or a felt tip pen for reinstallation later.

– To release the tension on the ribbed belt, turn the tensioner inthe -direction of the arrow- from underneath.

– Secure the belt tensioner using the locking pin -T10060 A- .

– Remove the ribbed belt.

– Disconnect the connector -1- from the A/C compressor regu‐lator valve.

WARNING

Refrigerant can cause serious personal injury.♦ Do not open the Air Conditioning (A/C) refrigerant circuit.

– Remove the A/C compressor bolts -arrows-.

Caution

Risk of damaging refrigerant lines and hoses.♦ Do not stretch, kink or bend the refrigerant lines and ho‐

ses.

– Secure the A/C compressor with the refrigerant lines attachedto the longitudinal member.

GTI and Eos

– Remove the radiator. Refer to ⇒ “5.11 Radiator“, page 271 .

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.Gr. 27 ; Removal and Installation .

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– Remove the after-run coolant pump bracket bolt -2-.

Note

The after-run coolant pump stays in the installed position.

– First, remove the bolt -1-, then the bolts -2 and 3- then thependulum support.

– Disconnect any remaining electrical wires necessary from theengine/transmission and set aside.

– Disconnect all coolant, vacuum and intake hose connectionsfrom the engine.

Caution

Always use the pins -T10359/2- and transmission support-3282- . Otherwise the engine will tip over.

• Install the pin -T10359/2- to the engine support -T10359- andthen install the transmission support.

– Attach the engine support -T10359- -1- to the engine andguide it into the mount.

– Seat the tensioner -3- in order to prevent the engine from tiltingout of the engine support -T10359- .

– Secure the engine support -T10359- -1- to the cylinder blockusing the bolt -3- and tighten it to approximately 20 Nm.

Note

The threaded hole for the bolt -1- was for the after-run coolantpump.

– Install the engine-/gearbox jack -V.A.G 1383 A- to the enginesupport -T10359- .

– Slightly lift the engine and transmission.

Note

Use a step ladder -VAS 5085- to remove the engine and trans‐mission mount to bracket bolts.



– Remove the engine mount to engine mount bracket bolts-arrows-.

– Remove the transmission mount to transmission mount brack‐et bolts -arrows-.

Note

♦ Verify that all hose and wire connections between the engine,transmission and body have been disconnected.

♦ To prevent damage, carefully guide the engine and transmis‐sion when lowering.

with a DSG®

• Pay attention to the selector lever cable.


– Move the engine and transmission as far as possible to the leftand slowly lower it.

Secure the engine onto the engine and transmission holder -VAS6095- when working on it. Refer to⇒ “4.3 Engine, Securing to the Engine/Transmission Holder“,page 32 .

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2011 cc the information in this article comes from a ......2/7/2018 engine, removing → removal and...

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