Volkswagen Workshop Service and Repair Manuals

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ The engine is removed forwards together with the gearbox.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.

• ‒ → Remove cover above camshaft housing -arrows-.
• ‒ Remove air cleaner:

=> Repair group 24; Servicing injection; Dismantling and assembling air cleaner

• ‒ Remove battery
• ‒ Remove battery tray.

• ‒ Unclip cable guide -from battery to bulkhead-.
• ‒ Release plus wire from battery to starter motor (is removed together with assembly).

• ‒ → Disconnect fuel supply and fuel return pipes at fuel rail, items -1- and -2-.

• ‒ Seal the pipes so that the fuel system is not contaminated by dirt etc.
• ‒ Observe rules for cleanliness .
• ‒ Disconnect clutch cable:

=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch mechanism

• ‒ Remove connecting hose for air cleaner/air intake connecting piece.
• ‒ Open and close the expansion tank sealing cap to release pressure in cooling system.

• ‒ Loosen or separate the following components:
• ‒ The hose from activated charcoal filter system to throttle valve control part
• ‒ The vacuum hose from brake servo to inlet manifold
• ‒ The collective connectors below thermostat housing
• ‒ The connector from engine speed sender below oil dipstick tube bracket, and pull connector out from retainer
• ‒ The connector from ignition transformer, from Hall sender and throttle valve control part
• ‒ The connector from coolant temperature sender, oil pressure switch and the engine oil temperature switch
• ‒ Remove noise insulation tray:

=> General body repairs; Repair group 50; Front body; Removing insulation tray

• ‒ Loosen or separate the following components:
• ‒ Connector for Lambda probes

• ‒ Drain coolant => Page 19-11 .
• ‒ Pull off coolant hose at engine with assembly tool for spring-type clamps VAS 5024.
• ‒ Loosen belt pulley securing bolts from power steering vane pump.
• ‒ Remove ribbed belt => Page 13-12 .
• ‒ Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing power steering vane pump.

• ‒ Remove left and right-hand drive shaft on gearbox and tie up:

=> Running gear, Axles, Steering; Repair group 40; Servicing front suspension; Removing and installing drive shafts

Vehicles with air conditioner

• ‒ Removing air conditioner compressor:
• ‒ Observe additional information and removal instructions =>Page10-15

• ‒ → Unbolt pendulum support from gearbox.

• ‒ Separate front exhaust pipe from exhaust manifold => Page 26-2 , exhaust manifold, front exhaust pipe and catalyst with attachments.
• ‒ Disconnect cable selector mechanism from gearbox.

=> 5-speed manual gearbox 085; Repair group 34; Servicing selector mechanism (cable selector mechanism); Removing and installing selector mechanism

• ‒ Pull vacuum and breather hoses off engine.
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.
• ‒ Remove securing clamps for power steering pressure pipe.
• ‒ Removing lock carrier with attachments:

=> General body repairs, Exterior; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

     Pulley end:
     3rd hole in hook at position 1

     Flywheel end:
     3rd hole in hook at position 5

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

• ‒ Remove power steering reservoir and tie up.

• ‒ → Unbolt assembly at gearbox and engine mountings.
• ‒ Lower assembly until it is released from the gearbox mounting.

Turn assembly slightly to left (engine forwards, gearbox rearwards) and lift engine carefully out forwards.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.