Engine: Service and Repair

REMOVING AND INSTALLING ENGINE

NOTE:
- This procedure is written for cars with manual transmission.
- Engine is removed from underneath.
- Clutch bell housing remains on engine.

REMOVAL
1. Set up hoist and lift car on the pick-up points.
2. Use fender covers.
3. Remove front wheels.
4. Disconnect battery ground cable.

Engine Harness:

5. Disconnect battery positive cable and push through splash wall with the rubber grommet.

Engine Harness Plugs:

6. Disconnect two plugs for engine wire harness. Remove wire clamps.

Control Unit:

7. Pull off wire plugs on control unit (In area of steering column).

Splash Wall:

8. Push wires and plugs through splash wall. Detach bracket with sensor wire on intake pipe to make engine removal easier.

Throttle Cable:

9. Disconnect throttle operating cable. Disconnect and pull off vacuum hose on brake booster.

Air Cleaner:

10. Disconnect air cleaner with air flow sensor on body and on coolant hose, and lay aside.
11. Remove distributor cap, distributor rotor and dust cap (to avoid damage).

Engine Ground:

12. Disconnect ground wire on splash wall.

Fuel Feed Line:

13. Pinch fuel return line with a standard hose clamp. Unscrew fuel feed line while counterholding.

Fuel Line:

14. Unscrew fuel return line.

Engine Support Tool:

15. Attach Special Tool VW 10-222 on front transport bracket of engine and hold engine tight in installed position.
16. Open heater regulating valve. Remove cap on coolant expansion tank.
17. Remove splash shield.

Exhaust Flange:

18. Remove exhaust assembly, by unscrewing flange, exhaust manifold/exhaust pipe connections and suspension points. Disconnect oxygen sensor plug and wire in metal lug on firewall.

Starter Wires:

19. Disconnect electric wires for starter. Unscrew and remove starter.
20. Unscrew clutch line clamp on engine.

Slave Cylinder:

21. Unscrew clutch slave cylinder on clutch housing (line remains connected).
22. Unscrew stabilizer on body and control arms, and remove.
23. Unscrew shield for right engine mount on front axle cross member.

Steering And Crossmember:

24. Unscrew universal joint on steering gear, tie rods on steering arms, upper hydraulic engine mount on engine braces, left and right control arms on front axle cross member, and remove front axle cross member with steering from underneath.
25. Cars with Air Conditioner: Unscrew poly-rib belt tensioner and take off belt.

A/C Compressor:

26. Unscrew compressor on console (don't disconnect refrigerant hoses). Suspend compressor from the spring strut with a piece of wire.

Coolant Drain:

27. Drain coolant through drain plug bore in radiator or the coolant hose and catch coolant.
28. Remove coolant hose on bottom of radiator.
29. Remove upper central tube mounting bolts.
30. Lower car.
31. Remove coolant hose on heater valve.

Heater Return Hose:

32. Remove coolant return hose for heater.
33. Remove coolant feed hoses on expansion tank.
34. Remove A/C fast idle hose.
35. Remove charcoal venting hose.
36. Remove vacuum line to vent valve and vacuum line to thermo valve at back of engine.
37. Remove upper radiator hose.
38. Remove radiator vent hose.
39. Remove wiring to temperature switch and both cooling fans.

Radiator Brackets:

40. Remove top radiator brackets and lift out radiator with cooling fans.

Special Tool US 1105:

41. Attach Special Tool US 1105 on engine (shorter end towards rear of engine).
42. Lift engine slightly and remove VW 10-222.
43. Remove lower central tube mounting bolts.
44. Lower engine, pull forward and remove from underneath.

INSTALLATION
Note the following for installation.
1. First insert transaxle/clutch housing mounting bolts, but do not tighten.

NOTE: Only tighten mounting bolts to final torque after hydraulic engine mount and front axle cross member have been mounted. Torque for mounting bolts: 42 Nm (30 ft lb). Front wheel alignment need not be checked after removal and installation of engine.

2. Make sure radiator fits correctly in rubber mounts.

Radiator Brackets:

3. Secure coolant hose (between radiator and expansion tank) on lock carrier with two straps.
4. Tighten bolts and nuts to specified torque.
5. Fill and bleed cooling system.