How do you remove the engine in a new beetle?

Answer 1

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.

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