Engine: Service and Repair

1. Disconnect battery ground cable.
2. Remove horn assembly, then the engine and transaxle cover plates.
3. Open heater control valve and coolant expansion tank cap, then drain cooling system.
4. Disconnect electrical connectors from fan and thermoswitch, then the coolant hoses from engine or expansion tank.
5. Remove radiator, then disconnect fuel lines and accelerator cable from injection pump. Disconnect accelerator cable from support.
6. On automatic transaxle models, remove accelerator cable with bracket.
7. On all models, disconnect cold start cable from pin and remove lockwasher from support.
8. Disconnect fuel shut-off solenoid electrical connector.
9. Disconnect gearshift indicator switch from bracket.
10. Disconnect vacuum hose between air filter and turbocharger at air filter.
11. Disconnect electrical connectors from oil pressure switch, coolant temperature sensors and glow plugs.
12. Disconnect coolant hose from engine.
13. Loosen power steering pump and bracket and position aside, leaving lines attached.
14. Disconnect hose from vacuum pump, then remove lock plate and disconnect clutch cable.
15. Remove attaching nuts from left and right engine mounts.
16. Remove alternator, then the engine stop bracket bolts.
17. On air conditioned models, loosen A/C compressor bracket bolts and position aside, leaving refrigerant lines connected.
18. On all models, remove turbocharger exhaust pipe and bracket from transaxle.
19. Remove starter motor, then the flywheel cover plate attaching bolts.
20. On automatic transaxle models, remove transaxle cover plate, then the torque converter mounting bolts.
21. On all models, install transaxle support bar VW785/1B or equivalent.
22. Attach tool No. US1105 or equivalent to engine, then raise engine and transaxle slightly using a suitable hoist.
23. Adjust transaxle support bar to contact transaxle, then remove transaxle-to-engine attaching bolts.
24. Separate transaxle from engine, then carefully lift engine assembly from vehicle.
25. Reverse procedure to install.