1.9L - Engine Assembly - Engine Code(s): Alh (Hatchback): Other Volkswagen Beetle A4

ENGINE, REMOVING

Special tools and workshop equipment required

1. Engine sling 2024 A
2. Engine/transmission support T10012
3. Holding fixture VW 313
4. Holding fixture engine/transmission support VW 540
5. Workshop crane VAG 1202 A
6. Drip tray VAG 1306 for VAG 1202 A
7. Torque wrench: 5 to 50 Nm VAG 1331
8. Torque wrench: 40 to 200 Nm VAG 1332
9. engine/transmission jack VAG 1383 A
10. Hose clip pliers VAG 1921
11. Step ladder VAS 5085
12. Grease G 000 100 (manual transmission only)
13. M10 X 25 / 8.8 Bolt
14. Cable tie

Note. After making sure that the ignition is switched OFF, disconnect the battery Ground (GND) strap. All cable ties which were opened or cut open to remove the engine/transmission assembly, must be replaced in the original position when installing the engine. Remove the engine/transmission assembly downward. Remove the engine cover. Remove power steering reservoir from battery support, thereby not having to loosen the fluid hoses. Attach coolant reservoir to upper radiator support. Remove the battery and battery hold-down. Remove Air Cleaner. Remove connecting pipe between the Charge Air cooler and intake manifold complete with EGR Vacuum Regulator solenoid valve -N18-.

Disconnect fuel supply and return lines at fuel filter.

Scheme 190

Seal off lines so fuel system is not contaminated by dirt etc.

Vehicles with manual transmission

Disconnect selector mechanism from transmission. Refer to [For transmission(s) 02E] REMOVAL AND INSTALLATION , or refer to [For transmission(s) 02J] SELECTOR MECHANISM , or refer to [For transmission(s) 0A4] Removal and Installation , or refer to [For transmission(s) 02M] Removal and Installation

Remove hydraulic clutch slave cylinder: refer to [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW (-item 12-), or refer to [For transmission(s) 0A4] SLAVE CYLINDER , or refer to [For transmission(s) 02M] CLUTCH SLAVE CYLINDER

Vehicles with automatic transmission

Remove Transmission Range selector lever cable from transmission: [For transmission(s) 09G] SELECTOR LEVER CABLE or refer to [For transmission(s) 01M] SELECTOR LEVER CABLE

All vehicles

Remove sound dampening tray: Description and Operation

Scheme 191

Drain engine coolant COOLANT, DRAINING AND FILLING

Remove line between charge air cooler and turbocharger.

Pull radiator hoses off engine using hose clip pliers VAG 1921.

Remove lower coolant hose from radiator.

Remove auxiliary filter, if available, on right side of vehicle.

Loosely unscrew pendulum support -arrows-.

Scheme 192

Pull vacuum and breather hoses off engine.

Disconnect all wiring from transmission, Generator and starter and move them to one side for clearance.

Remove front exhaust pipe FRONT EXHAUST PIPE AND CATALYST WITH ATTACHMENTS

Remove ribbed belt RIBBED BELT TENSIONER .

Remove power steering pump with bracket and lay to one side.

1. Hoses remain connected: «Removal and Installation»(ref-492756-S27087900932012080600000)

Remove right hand inner Constant Velocity joint protective cover from engine if installed.

Remove right-hand axle shaft and disconnect left-hand axle shaft at transmission: Removal and Installation

Unscrew mounting bolts for power steering pressure line.

Vehicles with air conditioning

Observe additional information and removal instructions A/C, ADDITIONAL INFORMATION AND REMOVAL INSTRUCTIONS .

Remove starter. Removal and Installation

All vehicles

Insert engine bracket 3396 into engine / transmission jack VAG 1383 A.

Remove coolant hose bracket and lower from cylinder block.

1. Thread hole is used to fasten engine bracket T10012

Thread on engine bracket T10012 using M10 X 25.5 / 8.8 nut and bolt.

Scheme 193

1. Attach to engine block with 25 Nm

Slightly lift engine/transmission assembly using jack VAG 1383 A.

Loosely unscrew engine mount (engine side) from top of engine bracket -arrows-.

Scheme 194

Note. Use tool VAS 5085 to remove the mounting bolts.

Loosely unscrew engine mount/transmission mount from transmission bracket -arrows- from top.

Scheme 195

Carefully lower engine/transmission assembly.

While lowering, carefully guide power steering fluid line past transmission.

Note. Carefully guide the engine and transmission assembly during the lowering process to prevent bodywork damage.

ENGINE, INSTALLING

Installation is reverse of removal, note the following during installation

Check whether centering dowels for engine/transmission are installed in cylinder block, install if necessary.

Install intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.

Scheme 196

Vehicles with manual transmission

Check clutch release bearing for wear, replace if necessary.

Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft using G 000 100.

Install hydraulic clutch slave cylinder: refer to [For transmission(s) 02J] HYDRAULIC SYSTEM ASSEMBLY OVERVIEW (-item 12-), or refer to [For transmission(s) 0A4] SLAVE CYLINDER , or refer to [For transmission(s) 02M] CLUTCH SLAVE CYLINDER

Install selector mechanism. Refer to [For transmission(s) 02E] REMOVAL AND INSTALLATION , or refer to [For transmission(s) 02J] SELECTOR MECHANISM , or refer to [For transmission(s) 0A4] Removal and Installation , or refer to [For transmission(s) 02M] Removal and Installation

If necessary adjust gear change cables: refer to [For transmission(s) 02E] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 02J] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 0A4] DIAGNOSIS AND TESTING , or refer to [For transmission(s) 02M] DIAGNOSIS AND TESTING

Vehicles with automatic transmission

Replace lock washer on selector cable anchorage.

Install selector cable on transmission, adjust if necessary: refer to [For transmission(s) 09G] SELECTOR LEVER CABLE or refer to [For transmission(s) 01M] Removal and Installation

All vehicles

When installing engine and transmission assembly, make sure sufficient clearance to axle shafts.

While raising, carefully guide power steering fluid line past transmission.

Align engine and transmission subassembly is transversely so there is a distance between engine mount -1- and engine bracket -2- of approx. 10 mm (installed condition).

Scheme 197

When bolting mount support arm to engine support and transmission console, engine and transmission mount must not be stressed (aligned parallel to each other).

Tightening torques FASTENER TIGHTENING SPECIFICATIONS

Remove left-hand axle shaft and disconnect right-hand axle shaft at transmission: Removal and Installation

Remove front exhaust pipe FRONT EXHAUST PIPE AND CATALYST WITH ATTACHMENTS

Remove connecting pipe between charge air cooler and intake manifold with EGR Vacuum Regulator solenoid valve.

Install power steering pump: Removal and Installation

Check electrical connections and routing: SYSTEM WIRING DIAGRAM

Install ribbed belt RIBBED BELT TENSIONER

Install sound dampening tray: Description and Operation

Fill with engine coolant COOLANT, DRAINING AND FILLING

Scheme 198

Special tools and workshop equipment required

1. Engine sling 2024 A
2. Engine/transmission support T10012
3. Holding fixture VW 313
4. Holding fixture engine/transmission support VW 540
5. Workshop crane VAG 1202 A
6. Drip tray VAG 1306 for VAG 1202 A

Scheme 199

Special tools and workshop equipment required

1. Torque wrench: 5 to 50 Nm VAG 1331
2. Torque wrench: 40 to 200 Nm VAG 1332
3. engine/transmission jack VAG 1383 A
4. Hose clip pliers VAG 1921
5. Step ladder VAS 5085
6. Grease G 000 100 (manual transmission only)
7. M10 X 25 / 8.8 Bolt
8. Cable tie