Volkswagen Workshop Service and Repair Manuals

The engine is removed upwards together with the gearbox.

• ‒ To avoid short circuits, disconnect the radio earthing strap at battery.

Note:

If applicable, first interrogate the radio antitheft coding.

Vehicles with windscreen washing water container on front right of engine compartment

• ‒ Take container with pump out of bracket and set down in plenum chamber.

Vehicles with dual headlights

• ‒ → Remove hedlight cap.

All vehicles

• ‒ Remove air cleaner and cover up carburettor.

Vehicles with air conditioner

Pay attention to additional assembly operations and instructions .

All vehicles

• ‒ → Drain coolant (heater control valve open):

• ◆ either via coolant hoses -1-
• ◆ or via flange for thermostat -2-

• ‒ → Pull coolant hose -1- off connection on cylinder head.
• ‒ Pull wiring off thermoswitch for electric fan.
• ‒ Remove radiator complete with radiator cowling and electric fan.
• ‒ Pull fuel line -2- off fuel pumb.
• ‒ Pull connector -3- off alternator.

• ‒ → Disconnect throttle cable -1- at carburettor and bracket (do not remove securing clip).
• ‒ Pull off fuel return line -2- at carburettor ( ä 07.79 at T piece).
• ‒ Unscrew vacuum reservoir -3- and place it on the engine.

With automatic gearbox

• ‒ → Detach throttle cable bracket on carburettor or on cylinder head but do not alter the adjustmen of the cable.

All vehicles

• ‒ Detach wires from distributor terminals 1 and 4 (high voltage), coolant temperature sender, oil pressure switch, thermo-switch for intake manifold preheating, intake manifold preheating, power supply terminal 15/separate connectors.
• ‒ Pull off coolant hoses for heating.
• ‒ Pull vacuum hose for brake servo off intake manifold.
• ‒ Remove drive shaft for speedometer (seal hole in gearbox).
• ‒ Pull vacuum pipe off connection at vacuum hose.

Vehicles ä 07.75

• ‒ Pull wire off TDC sender.

All vehicles

• ‒ → Disengage connecting rod -1- and selector rod -2- at gearbox.
• ‒ Loosen securing nut for relay lever -3- on the steering.

With automatic gearbox

• ‒ Move selector lever to "P".

• ‒ → Disconnect selector lever cable -1-.
• ‒ Disconnect throttle cable -2- and accelerator pedal cable -3-.
• ‒ Remove bracket -4-.

• ‒ → Detach torque converter from drive plate (3 screws).

Vehicles ä 07.80 (Scirocco ä 07.79)

• ‒ → Remove supports -16- and -17-.
• ‒ Unscrew exhaust pipe -18- at manifold.

Vehicles 08.80 ä ( Scirocco 08.79 ä )

• ‒ Remove clamping springs of ball joint at exhaust pipe => page 26-11 .

All vehicles

• ‒ Loosen securing nut -1- and remove relay lever with connecting rod.
• ‒ → Remove rear gearbox support -2-.
• ‒ Unscrew drive shafts -3- at gearbox and hang up on body with wire hook.
• ‒ Remove upper toothed belt guard.

• ‒ → Install lifting device as follows and raise slightly with crane.

• Pulley end:
• 4th hole of perforated bar in position 1
• Flywheel end:
• 2nd hole of perforated bar in position 6

Note:

Positions 1...4 in the support bracket face the pulley. The holes in the perforated bars are counted from the hook.

• ‒ → Disconnect clutch cable -1-.
• ‒ Disconnect wiring -2- from starter and from the reversing light switch -3-.
• ‒ Remove starter -4- and torque arm -5-.
• ‒ Remove left gearbox support -6-.
• ‒ Detach engine bearer on right from body.
• ‒ Turn engine slightly and lift it out carefully.

Note:

• ◆ The engine must be guided carefully when being lifted out to avoid damage to body or engine.
• ◆ On vehicles with 1B3 carburettor, particular care is to be taken to ensure that the pulldown unit does not come into contact with the body (danger of breakage).