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Volkswagen Workshop Service and Repair Manuals

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Securing engine to assembly stand > < Removing and installing engine

Polo Mk3

Notes on removing
Notes on removing
  Note
Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft code first if necessary.
–  The engine is removed forwards together with the gearbox.
–  With ignition switched off, disconnect earth strap from battery.
–  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.
–  Remove engine cover.
–  Remove battery.
–  Remove battery tray.
–  Disconnect fuel supply and return lines at fuel filter.
–  Remove connecting pipe between charge air cooler and intake connection.
–  Remove connecting pipe between air mass metre and turbocharger.
–  Pull connectors off thermo switch and radiator fan.
–  Remove noise insulation tray → Rep. Gr.50.
–  Drain coolant → Chapter.
–  Pull radiator coolant hoses off engine using hose clip pliers -V.A.G 1921- or spring-type clip pliers -VAS 5024A-.
Vehicles with air conditioning:
–  Observe additional remarks and installation work → Chapter.
Continuation for all vehicles
–  Remove lock carrier with attachments → Rep. Gr.50
–  Remove hydraulic clutch slave cylinder → Rep. Gr.30
  Note
Clutch pedal must not be depressed.
–  Disconnect selector mechanism from gearbox → Rep. Gr.34
–  Pull vacuum and breather hoses off engine.
–  Disconnect all electric wires 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.
   
–  Unscrew pendulum support -1- from gearbox.
–  Unbutton and remove connecting pipe between charge air cooler and turbocharger from sump.
–  Remove drive shafts from gearbox → Rep. Gr.40.
–  Remove poly V-belt → Chapter.
–  Unbolt power steering vane pump on bracket and place to one side, hoses remain connected → Rep. Gr.48
–  Remove exhaust pipe from turbocharger.
  N10-0228
–  Attach lifting tackle -2024 A- as follows and lift slightly with workshop crane -V.A.G 1202 A- or workshop hoist -VAS 6100-:
Belt pulley end: 2nd hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 7.
  WARNING
Use locking pins -arrows- to secure hooks and locating 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.
  N10-0229
–  Unbolt assembly from gearbox and engine mountings -arrows-.
–  Lower assembly until it is released from the gearbox mounting.
–  Pull assembly out forwards. When doing this, turn the assembly as necessary and lower it slightly.
  Note
When lifted out, the assembly must be carefully guided to prevent damage to the bodywork.
–  Secure engine to support clamp -VW 313- using engine and gearbox support -VW 540-.
  N10-0234

Securing engine to assembly stand > < Removing and installing engine