Engine: Service and Repair

REMOVING AND INSTALLING ENGINE (MANUAL TRANSMISSION)

Remove by lowering engine from car. The bell housing remains attached to the engine.

Removing

1. Align lifting platform pads beneath jacking points and raise car.

2. Place protective covers on fenders.

3. Unbolt and remove front wheels.

4. Disconnect battery/bodywork ground lead. Disconnect battery positive lead. Disconnect wire harness and push both cables with rubber grommets through splash wall. Open cable clips.

5. Unbolt panel in passenger-side footwell and remove. Unbolt carrier plate for DME control unit and disconnect control-unit plug. Disconnect 8-pin connector.









6. Slacken hose clamp for fuel return line and disconnect hose. Disconnect fuel feed while countering. Detach cable from tempostat servo motor. Disconnect series resistor/injection nozzle connector.





7. Disconnect breather hose for toothed belt cover at rear of lower section of air filter. Unbolt filter assembly as a unit and remove.





8. Remove air-flow sensor.





9. Slacken and remove ignition-distributor cap and rotor. (Mark installation position of rotor). Remove oil filter and ATF reservoir.

10. Remove throttle valve actuating cable complete with reversing roller and holder. Disconnect oxygen sensor plug connector. Slacken hose clamps at intake manifold and brake booster and disconnect hoses.





11. Remove cable clips from bulkhead. Disconnect two-pin and multi-pin connectors. Disconnect vacuum hose from tank breather valve.





12. Remove engine underguard.





13. Open coolant drain plug and catch coolant in a suitable container. Disconnect alternator breather hose.

14. Disconnect coolant hose at bottom right of radiator from engine and remove. Catch any coolant which may be left.

15. Disconnect electric leads from fan motors, detach fan-motor bracket from radiator and remove by lowering from car.

16. Slacken coolant hose and breather hose from top left of radiator and remove. Disconnect electrical connection from temperature switch to radiator. Disconnect coolant hose from expansion tank and remove.





17. Disconnect radiator at brackets and remove radiator by lowering from car.

18. Attach support beam 10-222 A to front transport bracket of engine and hold engine in installation position. Check that beam is correctly attached.





19. Detach Poly-rib belt tensioner from air-conditioning compressor and remove belt. Remove compressor from bracket and place to one side. (Do not disconnect refrigerant hoses).





20. Unbolt stabilizer with bracket from body and from control arms and remove. Disengage left and right tie rods.

21. Slacken hose clamps between ATF cooler and steering and disconnect line.





22. Disconnect servo pump from bracket, moving spacer sleeve forward to remove. Leave servo pump hanging from steering.

23. Disconnect left and right control arms from front-axle traverse and rear bearings and pull forward to remove. (Do not slacken bolts in bearing bracket).





24. Unbolt universal joint from steering, detach hydraulic motor mount from engine supports and lower front-axle cross member complete with steering and servo pump from car.





25. Disconnect leads from starting motor and remove starting motor.

26. Remove clutch actuating cylinder from bell housing. (Leave line connected). Unbolt and remove holder for line from upper crankcase half.

27. Disconnect exhaust from flange of exhaust manifold and disconnect exhaust extraction line. Remove oxygen-sensor cable from bodywork.





28. Disconnect flange downstream of catalytic converter and suspension and remove system.

29. Remove upper transaxle/bell housing mounting bolts.

30. Disconnect coolant hoses for heating above exhaust manifold and from cylinder head.

31. Attach VW Special Tool 3033 suspension beam to transport bracket of engine as follows:
Pulley end: Position 2
Flywheel end: Position 12
In position 2, the threaded rod is "beneath" the suspension beam. In position 12, the threaded rod is "above" the beam.

Engine Sling:

32. Tighten workshop crane e.g. Bilstein K750 H slightly to take part of engine weight and remove support beam 10 - 222A.

Note: Threaded rod of support beam 10 - 222A remains in front suspension eye.

33. Remove lower transaxle/bell housing mounting bolts.

34. Pull engine forward, push rubber sleeve out of firewall toward engine compartment and carefully pull wire harness out of passenger-side footwell.

35. Separate engine from central tube/central shaft and lower from car.


Installing

Note the following:

1. Carefully feed wire harness for DME control unit, 8-pin connector and multi-pin connector into passenger-side footwell.

2. Begin by screwing transaxle/bell housing mounting bolts into place, but do not tighten.

Note: Do not tighten mounting bolts fully until hydraulic motor bearing has been attached to the front-axle cross member. Tightening torque of mounting bolts: 42 Nm (3ft lblb).

3. Install control arms, pressing sleeve in rubber-metal bearing down slightly to facilitate installation.





4. Place a 4mm thick steel washer in each of the threaded connections between the right-hand engine support (viewed in the forward direction of travel) and the hydraulic motor bearing.

5. Check that the radiator is correctly seated on the rubber mounts.

6. Tighten nuts and bolts to the specified torques.
Tightening torques:
Stabilizer to aluminium control arm 25 Nm (18 ft lb)
Track rod to steering knuckle (locknut) 50 Nm (37 ft lb)
Steering - universal joint 30 + 5 Nm (22 + 3.6 ft lb)
Control arm to cross member 65 Nm (48 ft lb)
Cross member to body 85 Nm (53 ft lb)

7. Refill system with coolant and bleed system.





8. Fill reservoir with ATF and bleed steering system.

9. Run engine until it reaches operating temperature, check engine-oil level and coolant level, top up if necessary.