2.5L - Engine Assembly - Engine Code(s): Bpr & Bps (Hatchback): Other Volkswagen Beetle A4 facelift

ENGINE, REMOVING

Note. If the engine oil must be drained because of work performed on a removed engine, it should be performed with the engine installed. If the engine hangs on the engine lateral bracket T03001, the engine is not in the installed position and less engine oil flows out.

Special tools and workshop equipment required

1. Torque wrench (5-50 Nm) VAG 1331
2. Torque wrench (40-200 Nm) VAG 1332
3. Engine and transmission jack VAG 1383A
4. Spring clip pliers VAS 5024A or hose clip pliers VAS 6340
5. Step ladder VAS 5085
6. Engine holder bracket T03000
7. Hose clamps up to 25 mm dia. 3094
8. Old oil collecting and extracting device VAG 1782
9. Adapter set for engine and transmission support VW 540/1A
10. M8 x 100 bolt
11. Cable tie

Secure the engine to the engine stand. Refer to ENGINE, SECURING ON ASSEMBLY STAND .

Note. To perform the procedure, the ground cable must be disconnected from the battery. Check whether a coded radio is installed. If so, obtain the anti-theft code beforehand. The engine is removed downward together with the transmission. All cable ties which are opened or cut off when removing the engine, they must be replaced in the same position when installing the engine. Seal off the removed fuel, ventilation and vacuum lines so no dirt enters the system. Leave the key in the ignition lock to prevent the steering wheel from locking.

Remove the engine cover.

Remove the intake hose -1- and electrical connector -2- from the Mass Air Flow (MAF) sensor.

Scheme 60

Disconnect the hose -3- from the air filter housing.

Remove the bolts -4 and 6- and remove the air filter housing.

Remove the battery. Refer to Removal and Installation .

Remove the battery holder bolts -arrows- and holder.

Scheme 61

Vehicles Through MY 2009

Scheme 62

Remove the vacuum line -1-, ventilation line -2- and fuel supply line -3- and absorb any leaking fuel with a cleaning cloth.

Vehicles From MY 2010

Remove the ventilation line -2- and fuel supply line -3-. Absorb any leaking fuel with a cleaning cloth.

Continuation for All Vehicles

Note. Press the securing ring in to disengage the lines.

Disconnect all connectors -1- from the fuel injectors as well as connectors -2 and 7-.

Scheme 63

Remove the wiring harness -3- from the transport strap.

Open the clamp -6- and disconnect the hose.

Pull all clamps -4- and retaining ring -5- from locking mechanism.

Disengage and disconnect connectors from the ignition coils, camshaft adjustment valve 1 -N205-, intake manifold, throttle valve control module -J338-, Secondary Air Injection (AIR) solenoid valve -N112-, knock sensors and Engine Coolant Temperature (ECT) sensor -G62-.

Remove the ground (GND) strap bolt at the chain case cover and free up the wiring harness.

Vehicles with a Automatic Transmission

Disengage the connector from multifunction switch and disconnect.

Remove the selector lever cable from the transmission. Refer to [For transmission(s) 09G] SELECTOR LEVER CABLE or refer to [For transmission(s) 01M] SELECTOR LEVER CABLE .

Vehicles with a Manual Transmission

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

Remove the brace -1-.

Scheme 64

Remove the slave cylinder -arrows- and set it aside, do not open the line system.

Disconnect the backup light switch connector

Continuation for All Vehicles

Remove wiring harness from bracket on transmission and from starter.

Remove vacuum hose from vacuum pump.

Remove front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

Disconnect harness connector -2- for oxygen sensor in exhaust manifold.

Scheme 65

Remove heat shield at top of front exhaust pipe and free up wiring harness of oxygen sensor in exhaust manifold to engine.

Remove the right front wheel housing liner. Refer to Removal and Installation .

Remove the left and right drive axles. Refer to Removal and Installation .

Remove the rear bolt -arrow- for the engine mount through the wheel housing.

Scheme 66

Remove the pendulum support bolts -arrows-.

Scheme 67

Remove the subframe. Refer to Removal and Installation .

Drain the coolant. Refer to DRAINING AND FILLING .

Bring the lock carrier into the service position. Refer to Description and Operation .

Support the lock carrier using a sleeve -B-, 80 millimeter (mm) in length, for example, from VW 540/1 A and a M8 x 100 bolt -A-.

Scheme 68

Disengage and disconnect connectors from the generator, engine speed sensor and oil pressure switch. Free up the wiring harness.

Disengage and disconnect both connectors on the front of the transmission.

Disconnect the power steering line and remove the bracket for the wiring harness on the transmission.

Remove the nut -1- for the line -2- for the power steering at the engine and disconnect the line from the threaded pin.

Scheme 69

Remove the coolant expansion tank.

Empty the power steering reservoir using the VAG 1782 and remove it.

Remove the bracket nuts -2- for the power steering reservoir.

Scheme 70

Remove the nut -1- from the bracket. To do so, remove the right main head lamp. Refer to Removal and Installation .

Disconnect the intake and pressure line from the power steering pump. Seal the pump and lines with clean plugs.

Pull the pressure line to the left longitudinal member and securely it firmly.

Remove the nut -arrow- for the intake line -A- at the engine mount. Remove the intake line.

Scheme 71

Disconnect both coolant hoses from the heater core (quick release couplings).

Only slightly loosen the bolts of the mounts at the engine and transmission (less than 1 rotation).

Vehicles with Air Conditioning (A/C)

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

Disconnect the refrigerant line from the right longitudinal member at the top.

Disconnect the refrigerant line from the right longitudinal member at the bottom. Remove the nuts -1 and 2- to do so.

Scheme 72

Remove the ribbed belt. Refer to RIBBED BELT .

Remove the A/C compressor from the accessory bracket. Refer to Description and Operation .

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

Scheme 73

Note. To prevent damage to the condenser and also to the refrigerant lines/hoses, ensure that the lines/hoses are not stretched, kinked or bent.

Continuation for All Vehicles

Disconnect/clamp off all other connections - coolant, vacuum and intake hoses from the engine and transmission.

Install the T03000 as follows

Scheme 74

1. Remove the pin T03000/1 from T03000.
2. Attach the T03000 to the cylinder block with pin -3- and tighten bolts -1 and 2- hand tight.
3. Then install the pin T03000/1 and tighten it to 20 Nm.
4. Then tighten bolts -1 and 2- to 25 Nm.

Place the T03000 on the VAG 1383A and lift slightly.

Remove the engine mount bolts -arrows- from above and remove.

Scheme 75

Note. Use VAS 5085 to remove the bolts.

Remove both front bolts from the transmission mount.

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

Scheme 76

Carefully lower the engine with transmission downward and pull it forward while doing so.

When lowering, guide the exhaust manifold past at the steering gear.

ENGINE, INSTALLING

Engine and transmission mount tightening specifications. Refer to FASTENER TIGHTENING SPECIFICATIONS .

Installation is performed in the reverse order of removal. When doing this note the following

Vehicles with a Manual Transmission

Grease the splines of the input shaft lightly with grease G 000 100.

Check and install the clutch and clutch mechanism. Refer to [For transmission(s) 02E] CLUTCH, INSTALLING AND ADJUSTING or refer to [For transmission(s) 02J] CLUTCH or refer to [For transmission(s) 0A4] REMOVAL AND INSTALLATION or refer to [For transmission(s) 02M] CLUTCH .

Continuation for All Vehicles

First, firmly bolt the engine mount to the engine, then align the engine/transmission assembly free of tension via a shaking motion and tighten the bolts for the transmission mount.

Note. Tightening specifications of engine and transmission mounts. Refer to FASTENER TIGHTENING SPECIFICATIONS . Electrical connections and routing. Refer to Wiring .

Install the subframe. Refer to Removal and Installation .

Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER .

Install the left and right drive axles. Refer to Removal and Installation .

Install the Air Conditioning (A/C) compressor. Refer to Description and Operation .

Install the lock carrier. Refer to Description and Operation .

Install the bracket for the reservoir and power steering line. Refer to Specifications .

Install the ribbed belt. Refer to RIBBED BELT .

Vehicles with a Manual Transmission

Install the shift mechanism and adjust if necessary. Refer to [For transmission(s) 02E] SHIFT MECHANISM or refer to [For transmission(s) 02J] SELECTOR MECHANISM or refer to [For transmission(s) 0A4] SHIFT MECHANISM or refer to [For transmission(s) 02M] GEAR SELECTOR MECHANISM .

Install the clutch slave cylinder. Refer to [For transmission(s) 02E] CLUTCH, INSTALLING AND ADJUSTING or refer to [For transmission(s) 02J] CLUTCH or refer to [For transmission(s) 0A4] REMOVAL AND INSTALLATION or refer to [For transmission(s) 02M] CLUTCH .

Vehicles with a Automatic Transmission

Install the selector lever cable and adjust if necessary. Refer to [For transmission(s) 09G] SELECTOR LEVER CABLE or refer to [For transmission(s) 01M] SELECTOR LEVER CABLE .

Continuation for All Vehicles

Fill with coolant. Refer to DRAINING AND FILLING .

Install the noise insulation. Refer to Description and Operation .

Fill the power steering system. Refer to General Information .

Install the battery. Refer to Removal and Installation .

Adapt the Engine Control Module (ECM). Refer Vehicle diagnostic tester "Guided Functions".

Perform the vehicle system test. Refer to Vehicle diagnostic tester VAS 5051B "Guided Fault Finding".

Then, end "Guided Fault Finding".

Observe the safety precautions that apply to road tests.

Perform a test drive.

After that, perform a vehicle system test again and repair any occurring malfunctions.

Tightening Specifications