Removing engine (Passat, Passat CC): VW 1.4 (CAVA, CAVB, CAVC, CAVD, …)

🧭 Before you start

Fits: VW Passat CC (357, 2008–2012), VW Passat B7 saloon (362, 2010–2014), VW Passat B7 Variant (365, 2010–2014)

• Opens: coolant
• Special tools named: T40075A

Don't miss

• Mark position with a centre punch.
• Pull coolant hoses off engine with hose clip pliersVAS 6340.
• Press in securing ring to release fuel and breather lines.
• All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
• Clutch pedal must not be depressed.

🔧 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.

📐 60 workshop diagrams for CAVA

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Scribe dimensions (a) and (b) as shown.
2. Mark position with a centre punch.
3. Drill hole through the material with 13.0 mm bit.
4. Identify engine support with an (A) behind tool designation. [Note: Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.The engine is removed downwards together with the gearbox.All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.]
5. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all hoses, pipes and cables so that they are in their original positions.To avoid damage to lines/wiring, ensure sufficient clearance to all moving or hot components. — Remove noise insulation General body repairs, exterior50Body - front, noise insulation.

6. Lift engine cover panel at points (1) and pull it forwards in direction of (arrow).
7. Unbolt heat shield over turbocharger (arrows).
8. Remove air filter .
9. ⚠ When the engine is warm, the cooling system is under pressure.Hot steam/hot coolant can escape - risk of scalding.Cover filler cap on expansion tank with a cloth and open carefully to dissipate pressure. — Open and close expansion tank cap to release pressure in cooling system.
10. Drain coolant .
11. Release retaining clip (arrow).
12. Pull off coolant hose (1) from radiator. [Note: Pull coolant hoses off engine with hose clip pliersVAS 6340.]
13. Pull coolant hoses (arrows) off coolant expansion tank.
14. ⚠ Fuel supply lines are under pressure! Wear eye protection and gloves to avoid injuries and skin contact. Before loosening hose connections, wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection. — Disconnect the fuel supply line (1) and line from activated charcoal filter system solenoid valve 1N80(2) on the clutch. [Note: Press in securing ring to release fuel and breather lines.]
15. Release and pull off connector (2).
16. Unclip line from bracket (1).
17. Remove bracket (1) with fuel quality sender G446, unscrewing bolts (arrows) to do so.
18. Release fuel lines on fuel quality sender G446 and pull off
19. Seal lines so that no dirt is able to enter fuel system.
20. Observe rules for cleanliness .
21. Remove engine control unit J623.
22. Open all line guide fasteners (arrows).
23. Remove wiring from engine control unit.
24. Secure lines/wiring to engine with a cable tie.
25. Remove noise insulation General body repairs, exterior50Body - front, noise insulation.
26. Remove front left and right wheel housing liners General body repairs66Wheel housing liner; Removing and installing front wheel housing liner.
27. Connect battery Electrical system27Disconnecting and reconnecting battery
28. Remove battery and battery tray Electrical system27Removing and installing battery.
29. All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
30. Disconnect all electrical wiring from gearbox, alternator and starter and lay to side.
31. Pull off or disconnect all other electrical connections as necessary from engine and lay to side.
32. Pull vacuum and breather hoses off engine.
33. Release securing clip on right of charge air cooler in direction of (arrow) and pull off hose (arrow).
34. Release and pull off charge air hose in same way on left-hand side.
35. Loosen screw-type hose clip (arrow).
36. Pull off charge air hose (1) on left of charge air cooler (2).
37. Also loosen screw-type hose clip on right-hand side and pull off charge air hose.
38. Remove wiring for Lambda probe after catalytic converter G130 and for alternator from cable guides (arrows).
39. Disconnect connector for Lambda probe after catalytic converter G130.
40. Remove Lambda probe after catalytic converter G130(1).
41. Open hose clip (3) and remove charge air pipe (2).
42. Unbolt exhaust pipe from catalytic converter (arrows).
43. ⚠ Avoid damage to the flexible joint.Do not bend decoupling element more than 10°.Install decoupling element so that it is not under tension.Take care not to damage wire mesh on decoupling element. — Release connector (1) and pull off.
44. Unclip bracket (2) on subframe for electric wire to oil level and oil temperature sender G266.
45. Unclip locking mechanism (arrow).
46. Pull off wiring (1) on engine preheater heater element Z97(2).
47. Unclip wire (1) to engine preheater heater element Z97 on charge air pipe (2)(arrow).
48. Disconnect pendulum support (arrows).
49. Unscrew nuts (arrows A) on exhaust pipe (1).
50. Push front exhaust pipe (2) backwards out of mounting (arrows B).
51. Remove front exhaust pipe forwards.
52. Unbolt selector mechanism from gearbox: 34Repairing selector mechanism
53. Remove slave cylinder of hydraulic clutch: 30Repairing clutch mechanism [Note: Clutch pedal must not be depressed.]
54. Remove right drive shaft, unscrew left drive shaft at gearbox and tie up Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts
55. Remove selector lever cable 34Removing and installing selector lever cable.
56. Remove drive shafts Running gear, axles, steering40Repairing drive shafts; Removing and installing drive shafts.
57. Disconnect coolant pipes (1) from cylinder block and remove.
58. Undo and remove bolts (arrows) of cowling.
59. Release connector (1) and pull off.
60. Remove cowling downwards.

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