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1.9l - Engine Assembly - Engine Code(s): Alh (hatchback) Volkswagen New Beetle A4

Mechanical 16 illustrations ~1487 words

A/C, ADDITIONAL INFORMATION AND REMOVAL INSTRUCTIONS

CAUTIONDo NOT open the A/C refrigerant circuit.

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

To ease engine removal and installation without opening the A/C refrigerant circuit

Remove retaining clamp(s) from refrigerant lines.

Remove A/C compressor: Removal and Installation

Attach A/C compressor to vehicle body to provide stress relief for refrigerant lines/hoses.

Scheme 184

Scheme 184
Scheme 184

FASTENER TIGHTENING SPECIFICATIONS

Bolted jointTightening torque
Bolts, nutsM 610 Nm
M 825 Nm
M1040 Nm
M 1260 Nm
Variations on the above
Engine to transmission connecting boltsM1280 Nm
Torque converter to drive plate60 Nm
Axle shaft to flange / transmission40 Nm
Front exhaust pipe to turbocharger25 Nm

ENGINE AND TRANSMISSION ASSEMBLY MOUNTS

Tightening torques

Front engine/transmission mount

Scheme 185

Scheme 185: ENGINE AND TRANSMISSION ASSEMBLY MOUNTS
Scheme 185: ENGINE AND TRANSMISSION ASSEMBLY MOUNTS
1Mount to body ()40 Nm + 90° ( 1 / 4 turn)
2Mount/bracket to body25 Nm
3Mount to engine bracket ()60 Nm + 90° ( 1 / 4 turn)

Right rear engine/transmission mount

Scheme 186

Scheme 186
Scheme 186
1Mount to body (1)40 Nm + 90° ( 1 / 4 turn)
2Mount to body25 Nm
3Mount to transmission console (1)60 Nm + 90° ( 1 / 4 turn)
(1) Replace bolts
(1)Replace bolts

Pendulum support

Scheme 187

Scheme 187
Scheme 187
1Pendulum support to transmission (1)40 Nm + 90° ( 1 / 4 turn)
2Pendulum support to transmission (1)40 Nm + 90° ( 1 / 4 turn)
3Pendulum support to engine (1)20 Nm + 90° ( 1 / 4 turn)
(1) Replace bolts
(1)Replace bolts

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
CAUTIONObtain the radio anti-theft code from the customer BEFORE disconnecting the battery Ground strap.

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 188

Scheme 188
Scheme 188

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 189

Scheme 189
Scheme 189

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 190

Scheme 190
Scheme 190

Pull vacuum and breather hoses off engine.

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

Remove ribbed belt RIBBED BELT TENSIONER .

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

  1. Hoses remain connected: «Removal and Installation»(/volkswagen/new-beetle/a4-1997-2005/remont/manual-power-steering/#steering-hatchback__removal-and-installation)

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 191

Scheme 191
Scheme 191
  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 192

Scheme 192
Scheme 192

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

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

Scheme 193

Scheme 193
Scheme 193

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, SECURING TO ASSEMBLY STAND

Note. To work on the engine outside of the vehicle, attach engine to assembly stand using the holding fixture VW 313 along with the engine/transmission support VW 540.

Work sequence

Transfer engine/transmission subassembly to workbench via engine/transmission jack VAG 1383 A.

Scheme 194

Scheme 194: ENGINE, SECURING TO ASSEMBLY STAND
Scheme 194: ENGINE, SECURING TO ASSEMBLY STAND

Lower engine/transmission assembly such that transmission is supported.

Remove lower engine/transmission connecting bolt.

Push transmission off engine, while pushing torque converter out of drive plate.

Vehicles with automatic transmission

Remove nut from torque converter.

Clamp off ATF cooler hoses and disconnect at transmission cooler.

Seal off transmission cooler using clean plugs.

Secure torque converter to prevent it from falling out.

All vehicles

Attach Engine Sling 2024A engine sling using Bracket (Update to 2024A) 2024A/1 extension as follows and lift from engine/transmission jack VAG 1383 using workshop crane

Scheme 195

Scheme 195
Scheme 195
  1. Pulley end: 4th hole in hook at position 1
  2. Flywheel end: 4th hole in hook at position 8
CAUTIONSecure ALL hooks and locating pins with lock pins!

Note. Positions marked 1 to 4 on the bar must be located toward the pulley end of the engine. The holes in the hooks are counted up from the hook.

Secure engine to holding fixture engine/transmission support VW 313 using Holding Fixture VW 540 and supplementary kit VW 540/1.

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

Scheme 196: ENGINE, INSTALLING
Scheme 196: ENGINE, INSTALLING

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

Scheme 197
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).

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

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

Scheme 198: SPECIAL TOOLS
Scheme 198: SPECIAL TOOLS

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

Scheme 199
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

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