Removal the engine (VW Passat B6)

Note: For further operations, the ground wire must be disconnected from the battery. Therefore, first check whether the car radio is equipped with coding. If necessary, find out the security code that prevents theft.

Remove the crankcase guard.

Remove the front right and left fender liner.

Place the radiator frame in the service position.

The engine is removed downwards together with the gearbox.

Disconnect the battery.

Remove the battery and the battery holder frame.

After installing the engine, it is necessary to reinstall all cable clamps that were removed or cut during its dismantling.

Remove the air filter.

Open and close the expansion tank cap to relieve pressure in the cooling system.

Disconnect, unplug and hang up all electrical wires from the transmission, generator and starter.

Remove and disconnect all other existing electrical wires from the engine.

Caution: The fuel line is under pressure. To avoid injury and skin contact, wear protective glasses and gloves. Before disconnecting the hoses, wrap the connection with a rag. Then relieve the pressure by carefully loosening the connection.

Disconnect the hose from the solenoid valve 1 of the activated carbon canister at the throttle control module (Fig. 2.4).

Disconnect fuel line 1 and line 2 to the solenoid valve 1 of the absorber.

Cap hoses and lines to prevent dirt from entering the fuel system.

Observe the standards of cleanliness.

Disconnect the vacuum and ventilation hoses from the engine.

Disconnect the plug from the radiator fan.

Remove the wiper arms

Remove the water drain box casing/

Removal and installation of the engine control unit with theft protection

Disconnect plug 1 from the heated windshield control unit.

Slide the connector latches on the engine control unit to the edges and disconnect both connectors.



Unlock the high-voltage wire harness feedthrough and remove it by pulling it upwards (Fig. 2.5).




Open all cable clamps (Fig. 2.6).

Remove the wiring harness from the engine control unit.

Secure the wiring harness to the engine with a cable tie.

Remove the exhaust pipe.



Disconnect plug 1 from the oil level and temperature sensor (Fig. 2.7).

Unlock the holder 2 wires to the oil level and temperature sensor from the subframe.



[The original material is available on the portal: www.VWManual.ru]

Unscrew the rocker support (Fig. 2.8).

Unscrew the gear shift drive from the gearbox.

Remove the hydraulic clutch slave cylinder.

Note: Do not press the clutch pedal.

Drain the coolant.

Disconnect the water hoses from the engine using the VAS 5024A spring hose clamp pliers.

Remove the poly V-belt.

Remove the air conditioning compressor.

Note: The air conditioning system lines are not opened.

Secure the air conditioning compressor to the radiator frame.

Make sure that the hoses are not pinched.

Please follow the additional instructions and installation procedures.

Unscrew the right and left articulated shafts from the gearbox and tie them up.



Place the engine retainer on the VAG 1383 A engine and gearbox stand (Fig. 2.9).

Tighten the engine retainer to a torque of 20 Nm to the back of the cylinder block.

Note: Use a step ladder to remove the powertrain mount bolts.

Check that all hoses and wires between the engine, body and gearbox are disconnected.



Unscrew the power unit from the engine mount (Fig. 2.10).

Unscrew cable 1 from the gearbox mount.

Unscrew the power unit from the gearbox mount.

Pull the power unit forward as far as possible and slowly lower it down.

Note: Lower the power unit carefully to avoid damage to the body.