5 Cylinder Engine W/Manual Transmission

1. Disconnect battery ground cable.
2. Open heater control valve, remove expansion tank cap, and drain coolant by disconnecting lower radiator hose at radiator.
3. Loosen clamp and remove coolant hose from pipe, then remove engine to transmission attaching bolt securing pipe.
4. Remove upper radiator shroud and upper radiator hose.
5. Disconnect vacuum hose at brake booster.
6. Remove belt cover from power steering pump, then the power steering pump attaching bolts.
7. Disconnect vacuum hose at cruise control vacuum unit, if equipped.
8. Loosen and remove drive belts, then remove power steering pump, leaving hoses connected, and lay pump in cowl.
9. Disconnect coolant hose at thermostat housing.
10. Disconnect electrical connectors at oil pressure switch and control pressure regulator and position wiring out of way.
11. Disconnect clutch cable.
12. Remove upper engine to transmission attaching bolts, except one that is accessible.
13. Remove control pressure regulator, leaving fuel lines attached.
14. Loosen clamp and disconnect coolant hose from pipe adjacent to control pressure regulator.
15. Remove lower grille.
16. Remove engine stop bolts and the engine stop.
17. Remove upper and lower timing belt covers.
18. Attach tool 2084 or equivalent to crankshaft pulley.
19. Attach tool 2079 or equivalent to crankshaft bolt through grille panel opening and remove crankshaft bolt.
20. Remove two drive belt pulley bolts and loosen other two.
21. Tap two remaining bolts lightly and remove bolts, then remove pulley. Leave drive belt sprocket attached to crankshaft.
22. Remove adjusting bolt from alternator bracket.
23. Remove upper alternator bolt and lower alternator into lower radiator cover, leaving wires connected.
24. Remove alternator bracket from engine.
25. Loosen clamps and remove air duct.
26. Remove distributor vacuum unit hoses and disconnect coil high tension lead, electrical connector at cold start valve and wiring harness.
27. Pull out fuel injectors and remove cold start valve and wiring harness.
28. Remove fuel distributor with air flow sensor plate.
29. Disconnect fuel feed and return lines.
30. Disconnect PCV hose at valve cover, release upper air filter housing clips, and remove bolt securing air filter housing.
31. Disconnect wiring harness connectors.
32. Remove cover from right engine mount, loosen nuts on left and right engine mounts, and remove ground strap from engine mount.
33. On vehicles equipped with air conditioning, proceed as follows:
a. Loosen compressor drive belt adjusting bolts.
b. Disconnect oil temperature switch electrical connector.
c. Loosen bolt accessible through front grille opening.
d. Remove bracket from engine block and disconnect compressor clutch electrical connector.
e. Remove upper compressor attaching bolts and tie compressor out of way, leaving hoses attached.
34. Disconnect starter electrical connectors and position out of way.
35. Remove two front subframe bolts.
36. Remove nuts attaching exhaust pipe to manifold and the exhaust pipe hanger bolt.
37. Remove starter, then the lower engine to transmission attaching bolts.
38. Install transmission supporting tool VW785/1 or equivalent, attach suitable engine lifting device, and adjust support tool to contact transmission.
39. Remove remaining upper engine to transmission attaching bolt and the left side engine bracket.
40. Lift engine slightly, pry engine and transmission apart, and lift engine out while turning to left.
41. Reverse procedure to install, noting the following:
a. Coat mainshaft splines with suitable lubricant.
b. When installing drive belt pulley, align with mark on drive belt sprocket.
c. Coat threads and contact surface of crankshaft bolt with suitable locking compound.
d. Torque bolts and/or nuts as follows: A/C compressor to engine, 29 ft.lbs., alternator to engine and bracket, 14 ft.lbs., cold start valve, 7 ft.lbs., control pressure regulator, 14 ft.lbs., crankshaft bolt, 253 ft.lbs., engine stop on body/block, 32 ft.lbs., engine mounts, 32 ft.lbs., engine to transmission bolts, M8 14 ft.lbs., M10 32 ft.lbs., and M12 43 ft.lbs., exhaust pipe to manifold, 22 ft.lbs., exhaust pipe support, 22 ft.lbs., power steering pump, 14 ft.lbs., starter, 14 ft.lbs., subframe to body, 51 ft.lbs., and drive belt pulley, 14 ft.lbs.