Withdrawal

Given the characteristics of the different fuel injection systems relevant work should be carried out, depending on the engine design. Thus, always disconnects the injection between the engine and the body, regardless of the vehicle model year.

Removal of the engine must be performed in the following order:

- With the ignition off, disconnect the wires and battery;

- Check all electrical connections to determine the location of the studs to be cut. However, in order to re-establish them in their place, the latter should be marked accordingly. You can use instead of cable harnesses adhesive tape;

- Better to remove the engine cover, although this is not required. If this operation is carried out, then the pencil mark on the metal surface of the outer contours of the bonnet hinges to install the hood during assembly to its original position;

- Set the vehicle on a pit or hoist or brought under the front part of a fairly high and reliable support to provide access to its lower surface. Never place a support under the engine oil pan and transmission. The vehicle must be placed on a support when climbing, as described in Section. 1.5 shown in Fig. 6 and 7;

- Drain the cooling system. To do this, first unscrew the expansion tank to speed up the draining coolant. Release clamp the lower radiator hose and remove the hose. Disconnect the coolant hose from the thermostat housing. Crane heater must be opened, so that all the coolant to flow away from the heater unit. Save coolant for reuse, if its appearance and service life is not in doubt;

- To bring a cable clutch operation of engagement with the clutch lever, as described in Sec. 7. It also provides recommendations for the testing of adhesion, which should be carried out before installing the motor.

Cars equipped with assisted steering:

- Remove the servo steering according to the recommendations in the relevant section and secure it with wire bracket. Hoses thus remain on the pump. Remove the expansion tank steering and fix it.

Vehicles with air conditioning:

- Unscrew the screws of the expansion tank for the coolant, remove the tank and gently lower it;

- Remove all clamps highways refrigerant;

- Loosen the tension of the belt drive units on the front side of the engine and remove it as described in the relevant section;

- Remove the bonnet holder as described below;

- To dismantle the compressor is necessary to hold a series of preparatory work. Remove bracket generator, power steering pump and compressor. This means that after the dismantling of the power steering pump is necessary to remove the generator, then it is possible to dismantle the compressor. Last resting on one side with the holder of the bonnet without bending hoses. Fig. 14 shows the attachment nodes listed in Fig. 15 - the place fasteners.

Removing the engine bonnet

Because the engine is removed from the engine compartment up front, then the holder of the bonnet must be removed together with the parts attached to it. If you have an air conditioner should consider the above suggestions about placing parts after dismantling. Attachment points of the lock shown in Fig. 16. To remove the holder must do the following:

- Open all connectors and disconnect water hoses;

- Remove the cable the bonnet;

- Remove the front bumper. To do this, unscrew the indicated in Fig. 17 parts;

- Loosen the clamps highways of the air conditioner (if any);

- Unscrew the screws 2 (see. Fig. 16) and hex bolts 3;

- Carefully bring up forward lock holder assembly with all the details attached to it. When reassembling ensure that, when worn on the body of the lock holder is not deformed;

- Dismantle balancing suspension gear box. To do this, unscrew the indicated by the arrow in Fig. 18 nut 1, secure from turning the bolt head;

- Remove the air filter as recommended (see. Sec. 6). To mark the location of all hoses connected to the filter and remove the filter. All open holes closed with a clean cloth;

- Disconnect the thin section from the ignition coil and pull wire middle section of the coil;

- Disconnect the oil pressure sensor on the reed contact;

- Disconnect the terminals from the wire temperature sensor (cylinder head removed plug);

- Disconnect all the plugs in the engine compartment;

- Disconnect the wires from the switch terminals reversing lamps on the upper side of the gearbox (which pre-take the rubber cap). Label all wires connected to the terminals, so they can be attached, as before, and disconnect the wires from the terminals;

- Disconnect both hoses and coolant heat exchanger in the cylinder head after loosening the clamps (the highway and the thermostat housing). Wherein coolant may flow;

- Disconnect the vacuum hose from the brake servo intake manifold;

- Disconnect the fuel hose from the fuel return line filter and fuel supply;

- Disconnect the throttle cable. To do this, squeeze the control segment to the position at which you can unhook the cable. Then release the cable from the retainer;

- Disconnect the connector on the back cover of the generator after loosening the mounting clip. If the car is equipped with air conditioning, the latter has already been removed;

- Disconnect the terminals from the starter (large nut and thin wire section);

- Unscrew the outlet pipe from the knee and pull it from the arcuate support. Use of this insert with the extension, working from the lower side. Access to one of the nuts is very difficult;

- Disconnect the underside of the vehicle tachometer coil that is held by a cap nut of a large diameter. Remove the coil and pull it to the side;

- Disconnect drive gearshift. To do this, unscrew the bolt (fig. 19) securing the coupling and disconnect the system

;

- Disconnect the cable from the drive clutch control lever clutch, as described in Sec. "Clutch";

- Remove the cover that separates the breaker from the distributor, ignition distributor rotor and the dust cover to prevent them from damage during removal;

- Remove the bolt (fig. 20) securing the rear transmission mount and remove the support from the body and transmission;

- Disconnect drive shaft flange connection. For this purpose, the head of the hexagon socket ("8 mm"). Snap rolls wire to the suspension so that they do not interfere with the removal of the engine;

- Unscrew the flat wire of "weight" around the engine mount, without breaking its connection with the body. Unscrew the middle bolt bearing suspension;

- To raise the engine by means of respective ropes or belts. Volkswagen Service Centres use for this special collar. The cable can be started under the engine and gearbox, and thus raise the power unit;

- To connect a cable from the crane or hoist and slightly lift the power unit to the cable taut;

- Remove the left support of a transmission. To do this, unscrew the screws indicated in Fig. 20 by the arrow to the right;

- Slightly lift the power unit and expand so that you can remove it from the engine compartment up and forward. This power unit must constantly expand, raise or lower to spend it without interference by all neighboring nodes. Ensure that was not overlooked any one compound. When jam the engine and transmission in any location should immediately reduce stress and find out the cause of the lift;

- To disconnect the engine from the transmission. You must first dismantle the starter and clutch. After removing the connecting bolts to ask the assistant to support the engine and transmission drop down without letting it rest on the clutch.