Removing engine, Passat: VW 1.6 TDI (CAYC)

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Opens: refrigerant (A/C)

Don't miss

• Remove connector from engine wiring harness; to do this, engine control unit with protective housing must be be removed.
• The bolts (lower arrows) are removed at a later stage.Disregard (item 1).
• Remove bolts (arrows) and lay clutch slave cylinder aside. Do not open hydraulic system.
• Risk of destroying clutch slave cylinder.Do not press clutch pedal when clutch slave cylinder is removed. — Unscrew nut (1) for earth line.
• Danger of damage to air conditioner compressor, refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Unscrew refrigerant lines (arrows) from air conditioner compressor.

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all types of lines so that the original routing is restored.Ensure that there is sufficient clearance to all moving or hot components. — Remove engine cover .
2. With ignition switched off, disconnect battery earth strap Electrical system27Battery; Disconnecting and connecting battery.
3. Disconnect electrical connector on air mass meter G70.
4. Remove air filter housing with air mass meter and connecting pipe .
5. Unscrew bolts (arrows) and remove air duct from lock carrier.

6. Remove battery Electrical system27Battery; Removing and installing battery.
7. Remove connector from engine wiring harness; to do this, engine control unit with protective housing must be be removed.
8. Release feed-through for engine wiring harness (arrow) and pull off upwards.
9. Unscrew bolts (arrows) and remove battery mounting bracket (1).
10. Separate connectors.
11. Unscrew charge pressure regulation solenoid valve N75(arrows).
12. Place charge pressure control solenoid valve N75 with vacuum lines on engine.
13. Guide lines out of brackets on plenum chamber bulkhead and on turbocharger.
14. Unscrew bolts (upper arrows) for cowling. [Note: The bolts (lower arrows) are removed at a later stage.Disregard (item 1).]
15. Remove charge pressure regulating valve from plenum chamber bulkhead and lay it on engine together with vacuum hoses.
16. Slide the two clips in the direction of the (arrows) and remove cover from E-box in engine compartment.
17. Unscrew lines (arrows) at central electrics and lay lines on engine.
18. Open cable guide retainer (arrows).
19. Disconnect engine wiring harness connector (arrow) below left headlight.
20. Free electrical connector (1) and disconnect.
21. Open retainer (2) for wiring guide located below.
22. Remove wiring harness for engine control unit from wiring duct and place on engine.
23. Pull vacuum hose (arrow) off brake booster.
24. Remove selector mechanism from gearbox 34Selector mechanism; Removing and installing selector mechanism.
25. Remove bolt (3).
26. Remove bolts (arrows) and lay clutch slave cylinder aside. Do not open hydraulic system.
27. Guide clutch slave cylinder under strut (1).
28. ⚠ Risk of destroying clutch slave cylinder.Do not press clutch pedal when clutch slave cylinder is removed. — Unscrew nut (1) for earth line.
29. Disconnect electrical connector (2).
30. ⚠ Danger of scalding from very hot fuel.In extreme cases, the temperature of the fuel and the fuel lines can reach 100°C after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear eye protection. — Disconnect electrical connector (1) at fuel temperature sender G81.
31. Disconnect connector at pressure differential senderG 505(2), unscrew securing bolts (1).
32. Unclip lines for pressure differential senderG 505 out of upper toothed belt guard together with bracket (1).
33. Lay pressure differential senderG 505 on particulate filter together with bracket.
34. Remove securing clamp (1) between particulate filter and turbocharger.
35. Remove bolt (1).
36. Unscrew bolts (arrows) on engine mounting approx. 2 turns.
37. Unscrew bolts (arrows) on gearbox mounting approx. 2 turns.
38. Remove noise insulation:
39. Remove lower right and left wheel housing liner parts.
40. Remove charge air line, loosen hose clips (1) and (2) for this.
41. Remove charge air line, loosen hose clips (1) and (2) for this.
42. Seal open lines and unions with clean plugs from engine sealing plug setVAS 6122.
43. Disconnect electrical connector (1).
44. Unscrew bolts (lower arrows) and take out cowling downwards. [Note: Ignore (arrows).]
45. Disconnect electrical connectors (3) and (2)»if fitted«.
46. Disconnect electrical connector (1).
47. Extract refrigerant from air conditioning system Heating, air conditioning system00Repair instructions; Draining the refrigerant circuit.
48. ⚠ Danger of damage to air conditioner compressor, refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Unscrew refrigerant lines (arrows) from air conditioner compressor.
49. Unscrew bolts (1…3) and remove pendulum support.
50. Remove nuts (1 and 2).
51. Tie up particulate filter to rear.
52. ⚠ Avoid damage to the flexible joint.Do not bend decoupling element in front exhaust pipe more than 10°. — Unscrew bolts (arrows) and remove heat shield for right drive shaft.
53. Unbolt left and right drive shafts from flange shafts on gearbox.
54. Tie up left drive shaft.
55. Place right drive shaft on subframe.
56. Place drip tray for workshop hoistVAS 6208 under engine for this.
57. Disconnect bottom coolant hose leading to continued coolant circulation pump (loosen hose clip (arrow)) and drain off coolant.
58. Disconnect left upper coolant hose from radiator, lift retaining clip (arrow) when doing this.
59. Disconnect right lower coolant hose from radiator, lift retaining clip (arrow) when doing this, and drain off coolant.
60. Remove bolts (arrow up)(arrow down) and lift radiator up and out.

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