Engine, Removing And Installing

ENGINE, REMOVING

CAUTION: Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head gasket, radiator and heater core.

- disconnect ground cable from battery

- remove air cleaner with air flow sensor and air intake duct





- disconnect wire 1 at alternator

- disconnect following:
- plugs 2 at injectors
- plug 3 at throttle valve switch
- plug 4 at auxiliary air regulator

- disconnect hoses 5 and 6 at charcoal filter valve





- disconnect and plug fuel hoses 1 and 2

- remove accelerator cable from throttle valve lever

Automatic Transmission:
- remove circlip and spring 3 from accelerator rod.





- disconnect following:
- plugs 1 at injectors
- plug 2 at oxygen sensor
- plug 3 and 4 at ignition distributor
- plug 5 at oil pressure switch
- plug 6 at temperature sensor
- plug 7 at temperature sender
- plug at coolant level warning switch (not shown-located in coolant expansion tank)

- remove ground connectors 8





- block coolant hoses with clamps a
a=universal clamp-local supply





- block coolant hoses with clamps a
a = universal clamp-local supply

- open coolant expansion tank cap





- remove drain plugs 1 at cylinder heads and drain coolant





- disconnect brake booster line 1

- disconnect coolant hoses 2, 3 and 4

- remove coolant expansion tank 5

- remove engine/transmission bolt/nut 6 on left and right sides

Automatic Transmission:
- remove three bolts which attach torque converter to drive plate through hole on top of trans. housing (arrow)





- disconnect wiring 1 at starter

- remove accelerator rod 2

Vehicles With Power Steering:
- remove power steering pump with hose left attached, and place in engine compartment.

Vehicles With Air Conditioning
- remove compressor with hoses attached and place in engine compartment.





- remove plates 1 on left and right sides

- remove bolts, 2, do not remove plate 3

Syncro Only:

- remove rear skid plate under engine/transmission





- loosen mounting bolts for front transmission bracket three turns (arrow)





- loosen transmission mount bolt (arrow)





- attach VW 78511 B so that distance between support pad and transmission housing is about 120 mm (4 3/4 in.)

- support engine with US 612/5 and floor crane





- remove engine carrier bolts 15

- lower engine/transmission assembly until transmission rests on VW 785/1B





- when lowering, adjust angle of inclination on floor crane head and keep wiring harness aside so that it can pass oil filler tube

- remove nuts 2 of lower engine mounting bolts

- remove engine from transmission and lower it out of vehicle





- mount engine on repair stand with engine holder VW 307a

ENGINE, INSTALLING

NOTE: Proceed in reverse order of removing and note following.

Check clutch release bearing for wear and replace if necessary.

Syncro Only:
- clean joining faces of engine and transmission and lightly coat joining surface of engine with silicone adhesive seal Part No. AMV 176 000 O5
- lubricate clutch release bearing and main shaft splines lightly with MoS2 grease (do not lubricate guide sleeve for release bearing)
- replace all self-locking nuts on engine mounts
- check and adjust, if necessary, accelerator cable/throttle

Tightening Torques:

- engine to transmission 30 Nm (22 ft lb)
- engine carrier to body 25 Nm (18 ft lb)
- transmission mounts 30 Nm (22 ft lb)
- torque converter to drive place 20 Nm (15 ft lb)