Volkswagen Workshop Service and Repair Manuals > Polo Mk3 > Power unit | 4-cylinder injection engine (2-valve), mechanics | Engine assy,cylinder block,crankcase | Removing and installing engine

Notes on removing

–	First check whether a coded radio is fitted. If so, obtain anti-theft coding.

–	The engine is removed forwards together with the gearbox.

–	With ignition switched off disconnect battery earth strap and remove battery.

–	Place positive wire from battery to starter motor to one side (removed together with assembly).

Note

All cable ties which are opened or cut through when the engine is removed must be replaced in the same position when the engine is installed.

–	Drain coolant → Chapter.

–	Remove lock carrier with attachments: → General body repairs, exterior; Rep. Gr.50

–	Disconnect clutch cable: → Manual gearbox; Rep. Gr.30

Vehicles with power-assisted steering:

–	Unbolt power-assisted steering vane pump and secure to subframe with wire; hoses remain connected: → Running gear; Rep. Gr.48.

Vehicles with air conditioning:

–	Observe additional remarks and installation work → Chapter.

–	Unbolt pendulum support from gearbox.

Vehicles with power-assisted steering:

–	Tie-up power-assisted steering reservoir.

–	Attach lifting tackle -2024 A- as follows and lift slightly with workshop crane -V.A.G 1202 A-:

Belt pulley end: 2nd hole in hook rail at position -1-

Flywheel end: 2nd hole in hook rail at position -5-

WARNING

The hooks and locating pins must be secured with locking pins.

Note

t	The positions marked 1...4 on the bar must be towards the pulley end.

t	The holes in the hooks are counted up from the hook.

–	Unbolt assembly at gearbox and engine mountings.

–	Lower assembly until it is released from the gearbox mounting.

–	Pull assembly out forwards. Turn assembly and lift again lightly when doing this.

Note

When lifted out, the assembly must be carefully guided to prevent damage to the bodywork.

Before carrying out repair work, secure engine on assembly stand with engine and gearbox support -VW 540-.

Volkswagen Workshop Service and Repair Manuals