volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Vehicles with climatizing: > < Engine - remove and install

Polo Mk4

Notes refering to removal
Notes refering to removal
–  Engine is removed downwards, along with transmission.
  WARNING
For all installation jobs, especially in engine compartment, due to reduced space, pay attention to the following:
t  Place all types of hoses (i.e. fuel, hydraulics, activated charcoal filter, cooling fluid, brake fluid, vacuum) and electric cables in such a way that the original position is restored.
t  Ensure there is enough free space around all mobile or heated parts.
–  All open or cut cable braces for engine removal must be restored to original positions by the time of engine installation.
   
–  Remove engine bonnet in the -arrow- direction.
  Note
After operation, battery ground cable must be disconnected. Therefore, it is necessary to check whether a code radio equipment is installed. If necessary, the anti-theft system password must be requested in advance.
–  Disconnect battery ground cable with ignition off.
–  Open and close cooling fluid container cover, to relieve cooling system pressure.
–  Remove battery and battery support.
–  Remove connection hose between air filter and intake air tube.
–  Remove air filter.
  N13-0748
–  Remove engine lower cover.
–  Remove articulated shaft on the right and loosen the one on the left of transmission. → Chassis, Drive, steering; Rep. Gr.40
–  Lift left articulated shaft and tie it to stabilizer.
–  Remove front part from exhaust system tube with cataliser → Chapter remove and install exhaust system.
–  Drain cooling liquid → Chapter.
–  Remove engine hoses with assembly tool for Pliers -VAS 5024/-.
  N10-0343
–  Remove also radiator lower hose -arrow- .
–  Disconnect and loosen all transmission electrical connections, alternator and engine starter.
–  Disconnect all linking, cooling, vacuum and intake engine hoses.
–  Loosen receiving cylinder of hydraulic clutch: → 5 vel 02T mechanical transmission; Rep. Gr.30
–  Loosen transmission change lever: → 5 vel 02T mechanical transmission; Rep. Gr.34
  WARNING
t  Fuel and fuel tubes may become very hot (danger of burn injury)!
t  Fuel system is also pressurized! Before opening system, place cloth over connector and carefully loosen to relieve pressure!
t  For all installation jobs on the fuel system, wear safety goggles and gloves!
  N19-0370
–  Disconnect fuel supply and return tubes-arrows- on injection pump.
–  Seal tubes to prevent dirt from entering the supply system.
–  Follow cleaning rules → Chapter.
–  Disconnect and loosen remaining engine electrical connectors.
  S10-0063
–  Unscrew pendular support -arrows-.
  N10-0344

Vehicles with climatizing: > < Engine - remove and install