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2.0L - Engine Assembly - Engine Code(s): Aeg, Avh, BDC, Bev & Bgd (Hatchback): Other Volkswagen Beetle A4

Mechanical 10 illustrations ~1639 words

ENGINE, REMOVING

Special tools and workshop equipment required

  1. Lifting tackle 2024 A
  2. Engine mount T10012
  3. Holding fixture VW 313
  4. Engine and transmission holder VW 540
  5. Shop crane V.A.G 1202 A
  6. Drip tray V.A.G 1306
  7. Torque wrench V.A.G 1331
  8. Torque wrench V.A.G 1332
  9. Engine/transmission jack V.A.G 1383 A
  10. Pliers for spring type clips VAS 5024
  11. Spacers VW 540/1 B
  12. Step ladder VAS 5085
  13. Grease (vehicles with manual transmission) G 000 100
  14. Bolt M10 x 25 / 8.8
  15. Nut M10
  16. Cable tie

The engine is removed downward together with the transmission.

CAUTIONWhen doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Ensure sufficient clearance to all moving or hot components.

All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

First, check whether a coded radio is installed. If necessary, obtain the anti-theft coding.

Disconnect battery ground (GND) strap with the ignition switched off.

Remove engine cover.

Remove the power steering reservoir from the battery tray; be sure not to loosen the hoses.

Tie the reservoir to the lock carrier.

Remove the battery and the battery tray Removal and Installation .

WARNINGFuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.

Engine codes AEG, AVH, AZG and BDC

Disconnect the fuel supply line -1- and the fuel return line -2- from the fuel distributor.

Scheme 155

Scheme 155
Scheme 155

Engine codes BEV and BGD

Disconnect the fuel supply line at the connection -1-. To do this, push the securing ring -2- in the connection fitting -3-.

Scheme 156

Scheme 156
Scheme 156

Continuation for All

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

Remove air filter AIR FILTER ASSEMBLY OVERVIEW .

Remove upper part of intake manifold

  1. Engine code AEG «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(ref-492770-S14341956092012080600000) .
  2. Engine codes AVH, AZG and BEV «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(ref-492770-S29783048742012080600000) .
  3. Engine codes BDC and BDG «UPPER INTAKE MANIFOLD ASSEMBLY OVERVIEW»(ref-492770-S08983481142012080600000) .

Note. Seal the intake channels in lower part of intake manifold using a clean cloth.

With Manual Transmission

Remove the shift mechanism from the transmission, refer to [For transmission(s) 02E] SHIFT MECHANISM , or refer to [For transmission(s) 02J] Removal and Installation , or refer to [For transmission(s) 0A4] SHIFT MECHANISM , or refer to [For transmission(s) 02M] GEAR SELECTOR MECHANISM

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

Note. Clutch pedal must not be operated.

With Automatic Transmission 01M

Remove the selector lever cable from the transmission, refer to [For transmission(s) 01M] Removal and Installation .

With Automatic Transmission 09G

Remove selector lever cable from the transmission, refer to [For transmission(s) 09G] SELECTOR LEVER CABLE .

Continuation for All

Remove the center, left and right noise insulation Description and Operation .

Drain coolant COOLING SYSTEM, DRAINING AND FILLING .

Remove ribbed belt RIBBED BELT .

If equipped, remove the auxiliary fan on the right side of the vehicle.

Remove the mounting clamps for the power steering pressure line from the engine and transmission.

Disconnect the power steering pump on the bracket and tie it to the front piece; the hoses remain connected Description and Operation .

Vehicles with Air Conditioning

WARNINGThe air conditioning refrigerant circuit must not be opened.

Note. The refrigerant circuit must only be opened in workshops with trained personnel and the necessary range of tools and workshop equipment. To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate removal and installation of the engine without having to open the refrigerant circuit

Remove and install the refrigerant line retaining clamp(s).

Air conditioning compressor, removing and installing Description and Operation .

Secure A/C compressor to body so that the refrigerant lines/hoses are not burdened.

Scheme 157

Scheme 157
Scheme 157

Note. Shield bumper from damage using adhesive tape.

Continuation for All

Disconnect the intake hose and the coolant and vacuum hoses from the engine.

Remove the bracket with the secondary air injection (AIR) pump motor

  1. Engine code AEG through 05.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S04435919022012080600000) .
  2. Engine codes AVH, AZG, BEV and AEG from 06.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S10829632882012080600000) .
  3. Engine codes BDC and BGD «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S36392490162012080600000) .

Pull off/disconnect and lay aside all electrical harnesses from transmission, alternator, and starter.

Pull off/disconnect all electrical connections as necessary from engine and lay aside.

Remove bolts for pendulum support -arrows-.

Scheme 158

Scheme 158
Scheme 158

If equipped, remove the protective cap for the inner right CV joint from the engine.

Remove the right drive axle, and remove the left drive axle on the transmission Removal and Installation .

Remove the front exhaust pipe together with the catalytic converter

  1. Engine code AEG «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(ref-492749-S33016873892012080600000) .
  2. Engine codes AVH, AZG, BDC, BEV and BGD «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(ref-492749-S41390925392012080600000) .

If equipped, remove the oil pan guard OIL PAN ASSEMBLY OVERVIEW .

Set engine support T10012 on engine/transmission jack V.A.G 1383 A.

Remove the lower coolant hose bracket from the cylinder block. The threaded hole is needed for attaching the engine support T10012.

Fasten the engine support T10012 to the front of the cylinder block using an M10 x 25 / 8.8 bolt to approximately 40 Nm.

Scheme 159

Scheme 159
Scheme 159

Hand-tighten the nut on the exhaust side.

Lift engine and transmission slightly using the engine/transmission jack V.A.G 1383 A.

From above, remove the engine mount bolts -arrows- from the engine support.

Scheme 160

Scheme 160
Scheme 160

Note. Use step ladder VAS 5085 to remove bolts.

Remove transmission mount bolts -arrows- from transmission bracket from above.

Scheme 161

Scheme 161
Scheme 161

Carefully lower engine with transmission.

While doing this, route the power steering pressure line on the transmission.

Note. When lowering, carefully guide the engine and transmission to prevent damaging the body, hoses and lines.

ENGINE, INSTALLING

Installation is performed in the reverse order of removal, noting the following

CAUTIONWhen doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues: Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed. Ensure sufficient clearance to all moving or hot components.

Insert new centering sleeves for centering engine/transmission in cylinder block.

Engage intermediate plate at sealing flange and slide onto alignment bushings -arrows-.

Scheme 162

Scheme 162
Scheme 162

With Manual Transmission

If necessary, check centering of clutch drive plate.

Check clutch release bearing for wear and replace if necessary.

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

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

Install the shift mechanism, refer to [For transmission(s) 02E] SHIFT MECHANISM , or refer to [For transmission(s) 02J] Removal and Installation , or refer to [For transmission(s) 0A4] SHIFT MECHANISM , or refer to [For transmission(s) 02M] GEAR SELECTOR MECHANISM

If necessary, adjust the shift mechanism, 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

With Automatic Transmission 01M

Only use nuts for mounting the torque converter to the drive plate.

Install the selector lever cable to the transmission, refer to [For transmission(s) 01M] Removal and Installation .

If necessary, adjust the shift mechanism [For transmission(s) 01M] Diagnosis and Testing .

With Automatic Transmission 09G

Only use nuts for mounting the torque converter to the drive plate.

Install the selector lever cable to the transmission, refer to [For transmission(s) 09G] SELECTOR LEVER CABLE .

If necessary, adjust the shift mechanism [For transmission(s) 09G] Diagnosis and Testing .

Continuation for All

When installing engine/transmission assembly, check for clearance to subframe as well as to radiator.

While doing this, route the power steering pressure line on the transmission.

Align engine and transmission mountings ENGINE AND TRANSMISSION MOUNT, ALIGNMENT SPECIFICATIONS .

Secure the engine and transmission ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

Subframe tightening specifications ENGINE AND TRANSMISSION MOUNT TIGHTENING SPECIFICATIONS .

Install the right drive axle, and install the left drive axle on the transmission Removal and Installation .

If equipped, install the protective cap for the inner right CV joint.

Install the front exhaust pipe together with the catalytic converter

  1. Engine code AEG «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(ref-492749-S33016873892012080600000) .
  2. Engine codes AVH, AZG, BDC, BEV and BGD «EXHAUST MANIFOLD, FRONT EXHAUST PIPE AND ATTACHMENTS ASSEMBLY OVERVIEW»(ref-492749-S41390925392012080600000) .

Install the power steering pump Description and Operation .

Electrical connections and routing Wiring .

Install ribbed belt RIBBED BELT .

Install the secondary air injection (AIR) pump motor with the bracket

  1. Engine code AEG through 05.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S04435919022012080600000) .
  2. Engine codes AVH, AZG, BEV and AEG from 06.99 «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S10829632882012080600000) .
  3. Engine codes BDC and BGD «SECONDARY AIR INJECTION SYSTEM ASSEMBLY OVERVIEW»(ref-492749-S36392490162012080600000) .

Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .

Install the center, left and right noise insulation Description and Operation .

Without Electronic Power Control

Adjust accelerator pedal (AP) cable ACCELERATOR PEDAL CABLE, ADJUSTING .

Continuation for All

Check DTC memory of all control modules, repair all stored malfunctions, and erase DTC memory afterwards vehicle diagnosis, testing and information system VAS 5051 ; guided fault finding; vehicle system test, or vehicle diagnosis and service information system VAS 5052 ; on board diagnostic (OBD).

Perform road test and check DTC memory of all control modules again.

Note. Observe safety precautions that apply to road tests SAFETY PRECAUTIONS .

Scheme 163

Scheme 163: SPECIAL TOOLS
Scheme 163: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Lifting tackle 2024 A
  2. Engine mount T10012
  3. Holding fixture VW 313
  4. Engine and transmission holder VW 540
  5. Shop crane V.A.G 1202 A
  6. Drip tray V.A.G 1306

Scheme 164

Scheme 164
Scheme 164

Special tools and workshop equipment required

  1. Torque wrench V.A.G 1331
  2. Torque wrench V.A.G 1332
  3. Engine/transmission jack V.A.G 1383 A
  4. Pliers for spring type clips VAS 5024
  5. Spacers VW 540/1 B
  6. Step ladder VAS 5085

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