Layout of components on the 1.8-I Turbo petrol engine
- 1 - electrical connectors of ignition coils;
- 2 - grounding buses;
- 3 - fuel injectors;
- 4 - vacuum hose
The engine together with the gearbox is removed from the car downwards from the engine compartment. When removing the power unit, it is necessary to use a crane. The power unit can also be lowered using a special lift with engine holders.
To ensure sufficient working space under the vehicle, it is necessary to use four trestles or a vehicle lift with a platform or an inspection pit.
Depending on the manufacturing process and vehicle configuration, electrical wires, pipes and hoses may be arranged differently in the engine compartment. Therefore, before disconnecting electrical connectors and disconnecting pipes or hoses, it is recommended to mark them with adhesive tape.
Necessary special tools and auxiliary means:
- engine lifting crane;
- collet for band clamps;
- lifting grip;
- molybdenum disulfide based grease;
- torque wrench providing tightening torques of 5–50 Nm;
- torque wrench providing tightening torques of 40–200 Nm;
- clamp.
Warning: All clamps and straps that are unscrewed or cut when removing the engine must be installed in the same places when reassembling the engine, so their installation position can be marked with adhesive tape. When disconnecting electrical connectors, release the retaining wire and then disconnect the electrical connector.
Execution order
1. Remove the ground cable from the battery.
Warning: When the battery is disconnected, the contents of the memory cells, such as the radio code, are erased. Without the code, the radio can only be reconnected by the manufacturer.
2. Remove the battery.
3. Unscrew the battery holders and remove them (the nuts for fastening the holder are indicated by arrows).
4. Remove the starter.
5. Remove the air filter housing.
6. Unscrew the air intake going to the air filter.
7. Remove the lower engine compartment splash shield.
8. Unscrew the left and right drive shafts from the transmission flange. Using soft wire, tie the ends of the drive shafts to the anti-roll bar or body.
9. Drain the coolant from the cooling system.
Engine 1.8-I Turbo
10. Remove the pipes connecting the turbocharger to the pressurized air cooler and air cleaner. Loosen and remove the V-belt.
11. Unscrew the power steering pump from the bracket and use a soft wire to hang it from the body. Do not disconnect the hoses from the pump or kink the hoses.
Cars with air conditioning
12. Unscrew the upper (A) and lower (B) screws securing the air conditioning compressor and, without disconnecting the hoses from it, move the compressor to the side and secure it with soft wire.
Warning: Do not disconnect the air conditioning system pipes.
13. Remove the exhaust pipe and catalytic converter.
14. Remove the fuel supply hose.
15. Remove the upper engine cover.
16. Disconnect the electrical connectors from the ignition coils and fuel injectors. Unscrew the ground busbar (see figure Location of components on the 1.8-I Turbo petrol engine).
17. Disconnect the vacuum hose from the pressure regulator (see figure Location of components on the 1.8-I Turbo petrol engine).
18. Disconnect all vacuum hoses from the engine and turbocharger (engine 1.8-I-Turbo). If necessary, label the hoses before disconnecting them.
19. Disconnect all electrical connectors from the engine and transmission.
20. Mark and disconnect the supply (1) and return (2) fuel hoses from the fuel line.
21. Cover the ends of the fuel hoses with foil or suitable plugs to prevent dirt from getting into them.
22. Disconnect the cooling system hoses from the radiator.
23. Disconnect the hoses leading to the expansion tank from the engine and body and move them to the side.
24. Lift and secure the expansion tank together with the bracket.
Cars with manual transmission
25.. Disconnect the shift mechanism and clutch slave cylinder from the gearbox.
Warning: After removing the clutch slave cylinder, do not press the clutch pedal.
Cars with automatic transmission
26. Unscrew the brackets securing the power steering pressure line to the gearbox. Disconnect the automatic transmission control cable from the gearshift lever.
27. At the bottom of the engine compartment, unscrew the bolts (indicated by arrows) and remove the pendulum support that supports the engine and gearbox.
28. Raise the vehicle so that the distance between the vehicle and the ground is at least 60 cm.
Removal the power unit with a crane
29. Place a 30 x 40 cm wooden deck approximately 15 cm thick under the engine oil pan.
30. Using the special device, hook the power unit onto the lifting eyes of the power unit.
31. If there is no special device to support the engine, use a chain.
32. Raise the lifting mechanism so that the weight of the power unit is supported by the lifting mechanism.
Removal the engine with a special holder
33. The special holder is a VAG 1383A hydraulic lift with a T10012 engine holder. Install the special engine holder from below into the hole near the oil pan and secure the engine with nuts, tightening them to a torque of 25 Nm. Raise the engine holder so that the weight of the power unit is supported by the holder.
(The original text is available on the portal: www.VWManual.ru)
34. Unscrew the bolts (indicated by arrows), securing the right upper support of the power unit.
35. Unscrew the bolts (indicated by arrows) and remove the left support of the power unit.
36. Check that all electrical connectors and hoses connecting the engine and gearbox to the body are disconnected.
37. When removing the engine using a crane, move the power unit forward and carefully lower it onto a wooden stand. Secure the power unit so that it cannot tip over.
38. If necessary, disconnect the gearbox from the engine.
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