Volkswagen Workshop Service and Repair Manuals

Removing engine (Polo)   Note The engine is removed downwards together with the gearbox.

Special tools and workshop equipment required

t	Engine support -T10416- with adapters /1, /2, /3

t	Torque wrench -V.A.G 1331-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Engine and gearbox support -VAS 6095-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t	Stepladder -VAS 5085-

t	Torque wrench (40 … 200 Nm) -V.A.G. 1332-

Note Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.

–  Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.

–  Unbolt heat shield over turbocharger -arrows-. –  Pull hose -1- off at camshaft housing.

–  Open spring-type clip -2- and pull intake hose off. –  Pull intake hose out of intake connection. –  Unscrew securing bolt and pull air filter housing -4- upwards. –  Disconnect battery → Electrical system; Rep. gr.27. –  Remove battery and battery holder → Electrical system; Rep. gr.27.

–  Remove noise insulation securing bolts -arrows-. –  Remove front left and right wheel housing liners → General body repairs; Rep. gr.66. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter. –  Observe rules for cleanliness → Chapter.   WARNING 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.

–  Separate fuel supply line -1- and line to activated charcoal filter -2-. Press release tabs to do this. –  Pull coolant hoses off at heat exchanger behind intake manifold. –  Pull off connector -1-.

–  Pull vacuum hose -2- off at vacuum pump for brakes -V192--3-. Right-hand drive vehicles only –  Additionally pull vacuum hose off at brake servo. Continuation for all vehicles –  Secure vacuum hose to engine with cable tie. –  Pull off connector -1-.

–  Pull coolant hoses -2- off coolant reservoir. –  Unscrew securing bolts -3- and pull coolant reservoir upwards.

–  Release coolant hoses -arrows- at gearbox side and pull them off. –  Pull coolant hoses off at radiator and remove completely. –  Remove engine control unit → Chapter. –  Remove wiring harness from line guides and secure to engine with cable ties. –  Remove main fuse box in engine compartment → Electrical system; Rep. gr.97. –  Secure main fuse box to side of body with cable ties. –  Remove selector lever cable → Rep. gr.34.

–  Unscrew securing nuts on turbocharger -arrows-.

–  Remove charge air hose -arrow-. –  Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87   Note The air conditioning system lines must not be opened. –  Secure air conditioner compressor to lock carrier. –  Ensure that lines are not kinked. –  Disconnect connector -3- for Lambda probe after catalytic converter -G130-.

–  Also disconnect all further connectors at gearbox support. –  Unscrew securing bolts -1- for charge air pipe. –  Unscrew securing bolts -4- and remove bracket -5-. –  Pull upper charge air hose off turbocharger. –  Remove charge air pipe downwards. –  Press front exhaust pipe mountings from pins.

–  Loosen securing bolts of clamp -arrows- and slide to rear. –  Remove catalytic converter with front exhaust pipe downwards. –  Remove poly V-belt → Chapter. –  All cable ties that are opened or cut through when the engine is removed must be renewed/replaced in the same position when the engine is installed. –  Disconnect all electrical wiring from gearbox, alternator and starter and lay to side. –  Pull off or disconnect all other electrical connections as necessary from engine and lay to side. –  Pull vacuum and breather hoses off engine. –  Pull connectors off thermal switch and radiator fan. –  Remove right and left drive shafts → Running gear, axles, steering; Rep. gr.40.   Caution Bolt -1- must not be loosened.

–  Remove pendulum support securing bolts -arrows-. –  Remove subframe → Running gear, axles, steering; Rep. gr.40.

Engine support -T10416- with adapters -/1-, -/2- and -/3- is required to lower engine with gearbox.

–  Screw adapter -T10416/1- to stop into crankcase. –  Position the engine support -T10416- with adapters -/2- and -/3- on crankcase. –  Secure engine support -T10416- hand-tight to crankcase using a bolt -1-.

–  Tighten all bolts on engine support -T10416- to 20 Nm.   Note Adjuster nut -2- sets correct angle between pin on engine support -T10416- and engine and gearbox jack -V.A.G 1383 A-. –  Position engine and gearbox jack -V.A.G 1383 A- on engine support -T10416-. –  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.   Note To remove securing bolts use a stepladder -VAS 5085-. –  Unbolt earth wire -1-.   Caution Nut -2- must not be loosened.

–  Unscrew securing bolts -arrows- for engine mounting. –  Remove complete engine mounting.

–  Unscrew securing bolts -arrows- at gearbox mounting.   Note When lowering engine, guide it carefully to prevent damage. –  Carefully lower engine and gearbox. Secure engine to engine and gearbox support -VAS 6095- to carry out repairs. –  Unbolt gearbox. –  Secure engine on engine and gearbox support -VAS 6095-.