Engine, Removing And Installing
Engine, removingNOTE: Remove engine from top with the transmission attached.
CAUTION: Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head gasket radiator and heater core.
- disconnect battery ground strap
- remove power steering pump. and attach to body
- remove compressor mounting bolts together with mount and move to one side
- unscrew condenser from radiator, and move to one side
Do not disconnect
- hoses or brackets from power-steering pump
- A C hoses
- attach engine sling as shown and take weight with crane
CAUTION: Use cotter pins on hooks and holding pins (arrows) to secure tool.
- Pulley side lower (left arrow) second hole in vertical at position 2.
- Flywheel side lower (right arrow) second hole in vertical bar at position 6.
- The positions marked 1-4 on the bar must be towards the pulley side. The holes in the hooks are counted upwards from the hook.
CAUTION: Guide engine carefully when lifting to avoid damage to body.
- mount engine onto work bench with engine mount VW 540 if it is to be disassembled
Engine, installing
Install in reverse order of removal. Note the following:
- check clutch release bearing for wear, replace if necessary
- lubricate clutch release bearing driveshaft lightly with MoS2 grease
- check and ensure that the dowels for. centering engine/transmission are in cylinder block
- replace self-locking nuts for engine mounts
- lower engine onto mounts
CAUTION: Guide engine carefully when lowering to avoid damage to driveshaft, body.
- connect rear engine mount first, then connect transmission mount
- loosen front engine mount and mount bracket
- align all engine supports with mount bushing before tightening mount bolts
- adjust accelerator cable, Testing and Inspection
- reconnect all electrical connections
- check and adjust shift linkage
- fill coolant, Service and Repair
- check and adjust engine oil level, Capacity Specifications
- adjust engine timing/idle, For TIMING Testing and Inspection and for IDLE SPEED Testing and Inspection
- check and adjust headlights, if necessary