Subjects>Auto>European Cars

How do you remove the engine in a new beetle?

Anonymous

∙ 13y ago

Updated: 10/20/2022

Removal notes

First check whether a coded radio is installed. If so, obtain anti-theft coding. The engine is removed downward together with the transmission.
With ignition switched off, disconnect battery Ground strap.
All cable ties which are opened or cut open when removing engine must be replaced in same position when installing engine.
Remove engine cover.
Remove air cleaner:
Remove intake hose between Mass Air Flow (MAP) sensor -G70- and turbocharger.
Remove Power Steering fluid reservoir from battery holder without disconnecting hoses.
Fasten reservoir to lock carrier.
Remove battery and battery retainer.
Pull vacuum and breather hoses off engine.

WARNING:

Fire Hazard! Do NOT have anything in the area that can ignite fuel!
Fuel supply pipes are under pressure! Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

Pull off supply line/hose -1- (with white marking) and return line/hose -2- (with blue marking) and collect fuel that leaks out with a cloth.
Seal pipes so that fuel system is not contaminated by dirt etc.
Pull hose off solenoid valve.

Note: Press buttons on hose couplings to do this.

Loosen and remove intake hose (between charge air cooler and Throttle Valve Control Module -J338-) at Throttle Valve Control Module -J338-.
Disconnect harness connector for Intake Air Temperature (IAT) sensor -G42-, -1- and -4- for Throttle Valve Control Module -J338- -J338- below Throttle Valve Control Module -J338-.

Pull connector off Camshaft Position (CMP) sensor -G40- -arrow-.
Unbolt vacuum canister from cylinder head cover and pull from bracket.
Disconnect fuel injectors harness connector and unclip bracket rail from fuel distributor.
Unscrew Ground wire between ignition coil -1 and -2-.
Disconnect connectors from ignition coils.
Disconnect connector for speedometer Vehicle Speed Sensor -G22- at rear of transmission.
Remove center, left and right insulation tray:

Remove air duct to charge air cooler at lower right of long member.

Vehicles with manual transmission 02J

Disconnect selector mechanism from transmission.
Remove hydraulic clutch slave cylinder.

Vehicles with manual transmission 02M

Disconnect selector mechanism from transmission.
Remove hydraulic clutch slave cylinder.

Note: Clutch pedal must not be depressed.

Vehicles with automatic transmission

Remove selector lever cable from transmission:

Continued for all vehicles

Drain coolant.

WARNING:Observe proper disposal regulations!

Pull radiator coolant hoses off engine.

Note: The VAS 5024 assembly tool or VAG 1921 pliers are recommended for removing and installing the spring-type clamps.

Remove coolant hoses at heater core.
Remove coolant hose to coolant pipe at Throttle Valve Control Module-J338-.
Remove additional fan at right side of vehicle if present.
Disconnect both harness connectors for cooling fan at notch at left bottom.
Remove inter-connecting, coolant, vacuum and intake hoses on engine.

Remove connecting hoses -arrows- between secondary air pump/combi-valve and secondary air pump/air cleaner.

Note: Press buttons on hose couplings to do this.

Pull connector -1- off secondary air pump.
Remove secondary air pump motor and bracket.
Disconnect all electric wires from transmission, alternator and starter and move clear.
Remove securing clamps for power steering pressure pipe.
Remove ribbed belt.
Remove power assisted steering vane pump with bracket and lay to side; hoses remain connected.

Vehicles with air conditioner

WARNING: The air conditioner refrigerant circuit must not be opened.

Remove air conditioner compressor.
Observe additional notes and assembly work.
Remove generator.
Remove compact bracket including tightening element for ribbed V-belt.

Continued for all vehicles

Remove protective cover for right-hand inner constant velocity joint from engine.
Remove right-hand drive shaft and disconnect left-hand drive shaft at transmission.

Remove pendulum support -arrows-.
Remove front exhaust pipe with catalytic converter.

Fit engine bracket T 10012 onto cylinder block with a securing nut and M10 X 25/8.8 bolt and tighten to approximately 40 Nm.
Lift engine and transmission lightly using engine/transmission jack VAG 1383 A.

Unbolt engine side of assembly mount from engine carrier at top -arrows-.

Note: To remove securing bolts use step ladder VAS 5085.

Unbolt transmission side of assembly mount from transmission carrier at top -arrows-.
Carefully lower engine with transmission and guide power steering pressure line past transmission.

Note: Engine with transmission must be guided carefully when lowering to prevent damage to the bodywork.

Wiki User

∙ 13y ago

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