volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Vehicles with air conditioning > < Engine - remove and install

Polo Mk4

Removal - indications
Removal - indications
  Note
Check whether vehicle has code radio, if so consult anti-theft code before disconnecting ground cable from battery.
–  Engine is removed from the front, along with transmission.
–  With ignition off, disconnect ground cable from battery.
–  All cable fasteners that open or break during engine removal must be replaced and installed on the same locations when engine is installed.
–  Remove air filter body → Chapter.
   
–  Remove battery and battery support.
–  Open and close cooling fluid container lid to release cooling system pressure.
  WARNING
Fuel supply hose is under pressure! Before loosening hose junctions, place a cloth around them. Next, eliminate pressure removing hose carefully.
  A10-0116
–  Loosen fuel entrance tube 1 (press unlocking key).
–  Loosen hose from electro-magnetic valve 1 -N80- on intake collector.
–  Close tubes so that no dirt enters the fuel supply system.
–  Cleaning rules → Chapter.
–  Disconnect or loosen the following components:
t  Vacuum hose of servo-brake intake collector.
t  Engine rotation sensor connector sensor and intake collector pressure and intake air temperature sensor.
t  Ignition transformer connector, Hall sensor and butterfly command unit.
t  Connector of cooling fluid temperature sensor and oil pressure switch.
t  Injection valve connectors.
t  Lambda probe connector.
t  Double connector of detonation sensor (behind engine block).
–  Remove/disconnect and loosen all transmission electrical cables, alternator and start engine.
–  Remove/disconnect and loosen all other engine necessary electric cables.
–  Remove engine vacuum and ventilation hoses.
–  Remove lower engine compartment anti-noise.
–  Loosen front tube from exhaust collector → Chapter, exhaust collector, front exhaust tube and assembly parts.
  R10-0006
–  Loosen pendular support -arrows-.
–  Loosen transmission change mechanism: → 5-gear mechanical transmission 02T; Rep. Gr.34
–  Loosen starting cylinder of hydraulic gear: → 5-gear mechanical transmission 02T; Rep. Gr.30
  Note
Clutch pedal must not be activated.
–  Drain cooling fluid → Chapter.
–  Remove engine cooling fluid hoses using assembly tool for spring braces Pliers -VAS 5024/-.
  S10-0100

Vehicles with air conditioning > < Engine - remove and install