Removal

GENERAL:
- The engine is removed after being separated from the transaxle. When removing the engine, it is necessary to support the forward end of the transaxle. The procedure which follows describes the use of a Volkswagen special tool for this purpose. It is not necessary to remove the hood unless it will interfere with the type of lifting equipment being used.
- On air-conditioned cars, the air conditioning compressor should be removed and set aside without disconnecting the refrigerant lines, as described below, before removing the engine.

WARNING: Use extreme care when working beneath the battery drain tube on the right side of the engine compartment. The tube may contain battery electrolyte Battery electrolyte contains sulfuric acid, and can cause severe burns and damage to clothing. If electrolyte is spilled on your skin or clothing, flush the area at once with large quantities of water. It electrolyte gets into your eyes, bathe them with large quantities of clean water and call a physician immediately.

ENGINE REMOVAL:

1. Disconnect the negative (-) battery terminal, and then the positive (+) terminal. Remove the battery.
2. Remove the bolt holding the exhaust pipe to the support bracket on the engine. Disconnect the exhaust pipe from the exhaust manifold.
3. Drain the cooling system, and remove the coolant hoses connected to the engine.
4. Disconnect the harness connectors for the radiator cooling fan, the radiator thermoswitch, and the headlights. Remove the radiator with air duct and fan shroud.

Clutch Cable Adjusting Nut:

5. Loosen the clutch cable adjusting nut and disconnect the cable from the support bracket. Disconnect the cable from the clutch operating lever.

A/C Compressor:

6. On cars with air conditioning, remove the air conditioning compressor's V-belt. Without disconnecting any refrigerant lines, remove the air conditioning compressor from the engine. Using care to avoid kinking the refrigerant lines secure the compressor to the body using a length of rope or a stiff wire.
7. Remove the fuel injection components. With the main fuel lines attached, remove the air flow sensor and air filter housing and set it aside.
8. Disconnect the wires from the alternator and oil pressure switches, and label them.
9. On ClS-E and Digifant cars, disconnect the harness connector in the wire leading from the oxygen sensor.
10. On Canadian cars with CIS fuel injection, disconnect the harness connector from the control pressure regulator on the left (driver's) side of the engine cylinder block.

Harness Connectors:

11. Disconnect the harness connectors from the thermoswitches on the cylinder head coolant outlet, from the auxiliary air regulator and, on ClS/ClS-E cars, from the cold-start valve.
12. Disconnect the throttle cable from the throttle valve and cylinder head cover. On Digifant cars, disconnect the fuel injector connector(s).

Vacuum Hoses:

13. Disconnect the vacuum hoses shown, and label them. Disconnect the vacuum hose and electrical connections from the distributor.
14. On ClS/ClS-E cars, remove the fuel injectors (with lines connected). Plug the openings. Protect the injectors and lay them aside. Disconnect the fuel line from the cold-start valve. Loosen the connections slowly to relieve fuel pressure. Be prepared to catch spilled fuel.
15. On Digifant cars, disconnect the fuel supply and fuel return hoses. Loosen the connections slowly to relieve fuel pressure.Be prepared to catch spilled fuel.
16. Loosen the clamp on the charcoal canister and slide the canister toward the rear of the engine compartment.

Engine Stop At Front Of Engine:

Engine Mount:

17. Remove three upper engine-to-transaxle mounting bolts. Remove the engine stop as shown. Remove left and right engine mount nuts.
18. Remove the starter motor.
19. Remove the two lower engine-to-transaxle mounting bolts.
20. Disconnect any remaining electrical connections to the engine.

Bellhousing Cover Plate:

21. Working beneath the car, remove the bellhousing cover plate bolts, and remove the cover plate.

Transmission Support:

22. Install the transmission support as shown, or place a suitable transmission jack beneath the transaxle. Preload the support bar or raise the jack just enough to support the weight of the transaxle.

Engine Lifting Equipment:

23. Attach engine lifting equipment using the lifting points shown. Raise the engine slightly, so that its weight is supported by the lifting equipment.
24. Remove the remaining upper engine-to-transaxle mounting bolts.
25. Recheck, and if necessary adjust, the transmission support bar or transmission jack so that the weight of the transaxle is supported.
26. Separate the engine from the transaxle by moving the engine forward. Raise and remove the engine from the car. Proceed slowly so that the transmission mainshaft, the clutch assembly, and the car body are not damaged. Check frequently to make sure no hoses or wires are interfering with the engine's removal or being damaged.

WARNING: If the car is supported on jack stands, check often to make sure that it remains stable and well-supported while the engine is removed.