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-

t	Guide rods -T10093-

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

–  Unscrew securing bolts -arrows- of intake air duct and inlet connection on turbocharger. –  Pull off vacuum hose -1- beneath intake hose.

–  Remove securing bolt -2-. –  Pull air filter housing upwards. –  Disconnect battery → Electrical system; Rep. gr.27. –  Remove battery and battery holder → Electrical system; Rep. gr.27. –  Open and close expansion tank cap to release pressure in cooling system. –  Drain coolant → Chapter. –  Observe rules for cleanliness → Chapter.

–  Separate fuel supply line -1- and line to activated charcoal filter -2-. Press release tabs to do this.   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.

–  Open spring-type clips and pull coolant hoses -1- and -2- off. –  Push catch -3- underneath coolant hoses and pull hoses upwards. –  Put down coolant hoses to rear.

–  Pull coolant hoses -arrows- off at heat exchanger.

–  Release coolant hoses -arrows- at gearbox side and pull them off. –  Remove Lambda probe -G39--1- using Lambda probe open ring spanner set -3337-.

–  Unscrew upper securing bolt of alternator -2- and push alternator down slightly. –  Unscrew securing bolts -arrows- and remove heat shield from turbocharger.

–  Unbolt securing nuts at turbocharger -arrows-. –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Remove front left and right wheel housing liners → General body repairs; Rep. gr.66.

–  Open spring clip -1- at radiator for charge air system. –  Remove coolant pipe -2-. –  Open spring-type clips and pull off coolant hoses -1-.

–  Disconnect connector -2- from coolant circulation pump -V50-. –  Pull connectors -3- for knock sensor 1 -G61- and -4- off engine speed sender -G28-.

–  Pull connector -arrow- off oil level and oil temperature sender -G266-. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50.

–  Separate connection -1- for Lambda probe after catalytic converter -G130--2-.

–  Remove securing bolts -1-. –  Press mountings -2- from pins.

–  Loosen securing bolts of clamp -arrows- and slide to rear. –  Remove catalytic converter with exhaust pipe downwards. –  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.   Caution Bolt -1- must not be loosened.

–  Remove pendulum support securing bolts -arrows-. –  Remove right drive shaft, and unscrew left drive shaft from gearbox and tie up: → Running gear, axles, steering; Rep. gr.40. Vehicles with manual gearbox –  Disconnect selector mechanism from gearbox: → Rep. gr.34 –  Remove slave cylinder of hydraulic clutch: → Rep. gr.30   Note Clutch pedal must not be depressed. Vehicles with dual clutch gearbox –  Remove selector lever cable: → Rep. gr.34 Continuation for all vehicles –  Remove poly V-belt → Chapter. –  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.

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. Procedure –  Unbolt gearbox. –  Secure engine on engine and gearbox support -VAS 6095-.