1.4 TSI engine (EA111) · Removing and installing engine · Removing and installing engine

Removing engine (Polo)

Special tools and workshop equipment required

  • Engine support - T10416- with adapters /1, /2, /3
  • Torque wrench - V.A.G 1331-
  • Engine and gearbox jack - V.A.G 1383 A-
  • Engine and gearbox support - VAS 6095-
  • Drip tray for workshop hoist - VAS 6208-
  • Hose clamp pliers - VAS 6340-
  • Stepladder - VAS 5085-
  • Torque wrench (40 … 200 Nm) - V.A.G. 1332-
  • Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.
  • Unbolt heat shield over turbocharger -arrows-.
  • Pull hose -1- off at camshaft housing.
  • Open spring-type clip -2- and pull intake hose off.
  • Pull intake hose out of intake connection.
  • Unscrew securing bolt and pull air filter housing -4- upwards.
  • Disconnect battery ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting battery.
  • Remove battery and battery tray ⇒ Electrical system; Rep. gr. 27; Battery; Removing and installing battery.
  • Remove noise insulation securing bolts -arrows-.
  • Remove front left and right wheel housing liners ⇒ General body repairs; Rep. gr. 66; Wheel housing liner; Removing and installing front wheel housing liner.
  • Open and close expansion tank cap to release pressure in cooling system.
  • Drain coolant ⇒ 1.6 Draining and filling coolant (Polo).
  • Observe rules for cleanliness ⇒ 3.1 Rules for cleanliness.
  • Separate fuel supply line -1- and line to activated charcoal filter -2-. Press release tabs to do this.
  • Pull coolant hoses off at heat exchanger behind intake manifold.
  • Unplug connector -1-.
  • Pull vacuum hose -2- off at vacuum pump for brakes - V192- -3-.

RHD only

  • Additionally pull vacuum hose off at brake servo.

Continued for all vehicles

  • Secure vacuum hose to engine with cable tie.
  • Unplug connector -1-.
  • Pull coolant hoses -2- off coolant expansion tank.
  • Unscrew securing bolts -3- and pull coolant reservoir upwards.
  • Release coolant hoses -arrows- at gearbox side and pull them off.
  • Pull coolant hoses off at radiator and remove completely.
  • Remove engine control unit ⇒ 6 Engine control unit - J623-.
  • Remove wiring harness from wiring guides and secure to engine with cable ties.
  • Remove main fuse box in engine compartment ⇒ Electrical system; Rep. gr. 97; Removing and installing main fuse box in engine compartment.
  • Secure main fuse box to side of body with cable ties.
  • Remove selector lever cable ⇒ Rep. gr. 34; Removing and installing selector lever cable.
  • Unscrew securing nuts on turbocharger -arrows-.
  • Remove charge air hose -arrow-.
  • Remove air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87
  • Secure air conditioner compressor to lock carrier.
  • Ensure that lines are not kinked.
  • Disconnect connector -3- for Lambda probe after catalytic converter - G130-.
  • Also disconnect all further connectors at gearbox support.
  • Unscrew securing bolts -1- for charge air pipe.
  • Unscrew securing bolts -4- and remove bracket -5-.
  • Pull upper charge air hose off turbocharger.
  • Remove charge air pipe downwards.
  • Press front exhaust pipe support rings off pins.
  • Loosen securing bolts of clamp -arrows- and slide to rear.
  • Remove catalytic converter with front exhaust pipe downwards.
  • Remove poly V-belt ⇒ 1.3 Removing and installing poly V-belt (Golf Plus, Eos, Scirocco, Golf, Touran, Polo, Sharan, Passat, Passat CC, Golf Cabriolet).
  • All cable ties that are opened or cut through when the engine is removed must be renewed/replaced in the same position when the engine is installed.
  • Disconnect all electrical wiring from gearbox, alternator and starter and lay to side.
  • Pull off or disconnect all other electrical connections as necessary from engine and lay to side.
  • Pull vacuum and breather hoses off engine.
  • Pull connectors off thermal switch and radiator fan.
  • Remove right and left drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40; Repairing drive shafts; Removing and installing drive shafts.
  • Remove pendulum support securing bolts -arrows-.
  • Remove subframe ⇒ Running gear, axles, steering; Rep. gr. 40; Removing and installing subframe.

Engine support - T10416- with adapters -/1-, -/2- and -/3- is required to lower engine with gearbox.

  • Screw adapter - T10416/1- to stop into crankcase.
  • Position the engine support - T10416- with adapters -/2- and -/3- on crankcase.
  • Secure engine support - T10416- hand-tight to crankcase using a bolt -1-.
  • Tighten all bolts on engine support - T10416- to 20 Nm.
  • Position engine and gearbox jack - V.A.G 1383 A- on engine support - T10416-.
  • Lift engine and gearbox slightly using engine and gearbox jack
    • V.A.G 1383 A-.
  • Unbolt earth wire -1-.
  • Unscrew securing bolts -arrows- for engine mounting.
  • Remove complete engine mounting.
  • Unscrew securing bolts -arrows- at gearbox mounting.
  • Carefully lower engine and gearbox.

Secure engine to engine and gearbox support - VAS 6095- to carry out repairs.

  • Unbolt gearbox.
  • Secure engine on engine and gearbox support - VAS 6095-.