CJAA engine removal write-up

[Tdimrtwo]

Anyone know if there’s a video or write-up of CJAA engine removal? I need to swap mine out, and it would really help to have a step-by-step guide. I ordered a Haynes book, but I’m not sure how much in-depth coverage of the CJAA will be included.
For example, do you need to pull the engine and transmission together, or can the transmission be left in the car? Also, does taking the front end off of the car make it a lot easier? I think I’ve got all the required tools, I just need the overall direction to go.
If I recall correctly, when I swapped my ALH a few years back, taking off the bumper and radiator made the job much easier, and I pulled the transmission along with the engine. But, the CJAA looks much more complicated than my 03 Jetta wagon’s ALH.

 

[DrGERTol]

@Tdimrtwo -- Why not get the full VAG service documents from erwin.vw.com ? Get the 24-hour subscription for $35 and download as many VW PDFs as you need (or want) -- a much better value than the generic Haynes books, IMO. --g

 

[Tdimrtwo]

I haven’t heard of that, I’ll try it this afternoon.

 

[Tdimrtwo]

Maybe I'm looking in the wrong place, I see a link to the owner's manual, but nothing about a service manual.

 

[DrGERTol]

@Tdimrtwo -- After setting up an account & login credentials at https://erwin.vw.com/erwin/showCustomerRegistration.do , you need a subscription to access the service documentation -- get the one day (24 hour) subscription here: https://erwin.vw.com/erwin/showOrderFlatrate.do

Once your subscription starts, you have access the entire VW service document site to download as many PDFs as you need (or want) here: https://erwin.vw.com/erwin/showSearch.do --g

 

[Nuje]

Pro tip: Do not assume that "electrical" repair manual would include wiring; you need to change the document type drop-down to WIRING DIAGRAMS to get those.
(Ask me how I know....)

 

[oilhammer]

It is mostly the same procedure as an ALH, just more stuff to disconnect. Not really hard at all. I take the front of the car off.

 

[Tdimrtwo]

Thanks for the info, I've downloaded the service manual and will use it to do the engine swap.

 

[oilhammer]

Keep in mind, the service manual often makes the assumption you have all the shop equipment and SSTs necessary to do the job just as a dealer or service professional would have. Sometimes the DIYr has no access to or has to improvise with certain items and tasks.

Like I said, the CJAA is not fundamentally that much different than the ALH, so if you successfully did that, you shouldn't have much trouble with this. They mount in the car essentially the same.

 

[Tdimrtwo]

Thanks oilhammer, I thought so as well I. I saw that they had a list of tools required at the beginning of the removal procedure, but I could see that many weren’t essential or could be improvised.

As far as I can tell, the engine is locked, but the transmission is OK. So, would you recommend removing the engine by itself or engine and transmission together?

 

[oilhammer]

I always take the engine and transmission out as a unit together. Slide it right out the front.

 

[borninabus]

be aware that a failed DMF can cause the engine to lock up.

 

[turbodieseldyke]

Why leave a support bar up there just to hold the tranny, and then upon reinstallation, fight to align everything with limited working space?

 

[Tdimrtwo]

Thanks for the good advice. Is there a way to see if the DMF has caused the lockup without pulling the engine/transmission assembly? Maybe it doesn’t really matter, since I’ll be able to tell when I separate the engine from the transmission. I’ve pulled ALH and BEW transmissions alone to replace clutches, but I can see how pulling the engine alone wouldn’t be practical.

 

[borninabus]

in theory, you could loosen the trans from the engine and pull the trans off a bit and see if the engine starts to spin or if something falls out.

 

[Tdimrtwo]

Thanks borninabus, I’ll do that tonight.