Arrangement of elements on a 1.8-I Turbo gasoline engine
- 1 - electrical connectors for ignition coils;
- 2 - ground bus;
- 3 - fuel injectors;
- 4 - vacuum hose
The engine together with the gearbox is removed from the car down from the engine compartment. When removing the power unit, a crane must be used. Also, the power unit can be lowered using a special lift with engine holders.
In order to provide sufficient working space under the vehicle, it is necessary to use four jack stands or a car lift with a platform or a viewing hole.
Depending on the course of manufacture and vehicle equipment, electrical wires, pipelines and hoses may be located in the engine compartment in different ways. Therefore, before disconnecting electrical connectors and disconnecting pipes or hoses, it is recommended to mark them with adhesive tape.
Necessary special tools and aids:
- crane for lifting the engine;
- collet for tape clamps;
- lifting grip;
- lubricant based on molybdenum disulfide;
- torque wrench providing tightening torques of 5–50 Nm;
- torque wrench providing tightening torques of 40–200 Nm;
- clamp.
Warning: All clips and clamps that are unscrewed or cut when removing the engine must be installed when assembling the engine in the same places, so their mounting position can be marked with adhesive tape. When disconnecting the electrical connectors, release the fixing wire and then disconnect the electrical connector.
Order of execution
1. Remove the ground wire from the battery.
Warning: Disconnecting the battery will erase the contents of the memory locations, such as the radio code. Without a code, the radio can only be reconnected by the manufacturer.
2. Remove the battery.
3. Unscrew the battery holders and remove them (holder fastening nuts 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 mudguard of the engine compartment.
8. Unscrew the left and right drive shafts from the gearbox 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 filter. Release the tension and remove the V-belt.
11. Unscrew the power steering pump from the bracket and, using a soft wire, hang it from the body. Do not disconnect hoses from pump or kink hoses.
Vehicles with air conditioning
12. Unscrew the top (A) and lower (IN) 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 piping.
13. Remove the exhaust pipe and catalytic converter.
14. Remove the fuel supply hose.
15. Remove the top engine cover.
16. Disconnect the electrical connectors from the ignition coils and fuel injectors. Unscrew the ground bar (see fig. Arrangement of elements on a 1.8-I Turbo gasoline engine).
17. Disconnect the vacuum hose from the pressure regulator (see fig. Arrangement of elements on a 1.8-I Turbo gasoline engine).
18. Disconnect all vacuum hoses from the engine and turbocharger (1.8-I-Turbo engine). If necessary, mark the hoses before disconnecting them.
19. Disconnect all electrical connectors from the engine and transmission.
20. Label and disconnect feeder (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 entering them.
22. Disconnect the pipes of the cooling system from the radiator.
23. Disconnect the hoses going 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.
Vehicles with manual transmission
25.. Disconnect the shift mechanism and clutch slave cylinder from the transmission.
Warning: After removing the clutch slave cylinder, do not depress the clutch pedal.
Vehicles with automatic transmission
26. Unscrew the brackets securing the power steering pressure pipe to the gearbox. Disconnect the automatic transmission control cable from the transmission lever.
27. Unscrew the bolts at the bottom of the engine compartment (indicated by arrows) and remove the pendulum support supporting the engine and transmission.
28. Raise the vehicle so that the distance between the vehicle and the ground is at least 60 cm.
Removing the power unit with a crane
29. Place a 30 x 40 cm wooden deck about 15 cm thick under the engine oil pan.
30. Using the special tool, hook the power unit on the lifting eyes to lift the power unit.
31. If special tools are not available to support the engine, use a chain.
32. Raise the load handler until the weight of the power package is supported by the load handler.
Removing 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 just enough so that the weight of the power package is supported by the holder.
34. unscrew the bolts (indicated by arrows), fastening the right upper support of the power unit.
35. unscrew the bolts (indicated by arrows) and remove the left power unit support.
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 in such a way as to prevent it from tipping over.
38. If necessary, disconnect the gearbox from the engine.
Visitor comments