Removal

GENERAL:
- The engine and transaxle are removed as a unit, and separated from each other for additional work once they are removed. The assembly is lifted out from the top, but 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 and condenser are removed and set aside without disconnecting the refrigerant lines. On cars with power steering, remove the power steering pump and fluid reservoir. Set them aside without disconnecting the power steering fluid lines.

To Remove:
1. Disconnect the negative (-) battery terminal, and then the positive (+) terminal. Remove the battery.
2. Loosen the fuel filler cap in order to relieve fuel tank pressure.
3. Remove the rubber duct that connects the throttle valve assembly to the fuel injection system's mixture control unit.
4. Drain the cooling system, and remove the coolant hoses connected to the engine.

CAUTION: Volkswagen advises that engine coolant must not be reused when replacing the cylinder head, the cylinder head gasket or the engine.

5. Disconnect the electrical connectors for the radiator cooling fan and the radiator thermoswitch, then remove the radiator and fan assembly.
6. Remove the wiring from the alternator, and then remove the alternator.
7. At the front of the engine, disconnect wiring from the oil pressure switch, the coolant thermoswitch and, on engines with CIS fuel injection, the control pressure regulator. Remove the intake air preheat pipe.
8. On cars with air conditioning, remove the compressor drive belt. Without disconnecting any refrigerant lines, remove the air conditioning compressor from the engine. Set it aside on the fender, using care to avoid kinking the refrigerant lines. Tie the compressor down to hold it.
9. At the left side of the engine, disconnect the coolant temperature sensor wires, the heater hoses, and the starter wiring harness. Disconnect the vacuum hoses, the center coil wire, and the Hall sender connection on the distributor.
10. Detach the fuel lines from the control pressure regulator and the cold start valve. Disconnect the wiring from the cold start valve, the auxiliary air regulator, and the full-load enrichment switch. Disconnect the vacuum hoses for the brake vacuum servo and the vacuum amplifier. Remove the PCV hose.

WARNING: Fuel will be expelled. Do not smoke or work near heaters or other fire hazards. Have a fire extinguisher handy.

11. Disconnect the oxygen sensor connector behind the cylinder head. Remove all engine ground connections.
12. Remove the four fuel injectors.
13. Remove the speedometer drive cable from the transaxle housing.
14. On models with manual transmission, detach the clutch cable and shift linkage. Remove the accelerator cable from the engine.
15. On models with automatic transmissions, place the selector lever in the "Park" position. Remove the accelerator cable and the selector lever cable.
16. Disconnect all remaining electrical connections to the engine and transaxle, including the wires for the starter solenoid and the back-up light switch. Remove the horn.
17. Detach the exhaust front pipe from the exhaust manifold.
18. Working under the car, remove the drive axles, and then reinstall the ball joints into the wheel bearing housings so that the car can be lowered onto its wheels.
19. On cars with manual transmission, remove the starter.
20. Remove the engine/transaxle front mounting.

Engine Sling [VW Special Tool 2024A]:

21. Prepare to lift the engine by connecting the Volkswagen engine sling or its equivalent to the lifting points shown in the image. Always secure connecting pins and hooks with cotter pins as shown.
22. Raise the hoist slightly, so that the weight of the engine and transaxle assembly is supported by it.

Rear Transaxle Mount Nuts:

23. Remove the rear transaxle mount as shown in the image.