Recommendations for removing the engine
Please read this section carefully before starting work.
If the engine is removed for repair, it is necessary to select a place for work, provide space for maintenance and storage of spare parts. Repairs are recommended to be carried out at a workshop or in a garage with a flat, horizontal floor with a clean hard surface.
Before removing, clean and wash the engine and engine compartment. To remove the engine, use a lifting device that allows you to safely lift the power package.
If you are removing the engine for the first time, you must invite an experienced specialist. Some work should be done with an assistant.
All clamps and clamps that are damaged or cut when removing the engine are replaced with new ones when assembling the engine.
The engine is removed forward without a gearbox.
Drained coolant must be collected and disposed of.
Before disconnecting the battery, find out if you have a radio activation code.
Withdrawal
Turn off the ignition and disconnect the wire «masses» from the battery.
Remove the expansion tank cap.
Pic. 3.1–1. The location of the fastening latches of the lower mudguard of the engine compartment
Release the fasteners shown by the arrows in fig. 3.1-1, and remove the lower mudguard of the engine compartment.
Pic. 3.1–2. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment
Unscrew the two bolts and remove the bracket for the lower mudguard of the engine compartment (pic. 3.1–2)
Install a coolant drip tray under the engine.
Pic. 3.1–3. Duct location (1) and collars (2 and 3) coolant hose fittings
Loosen clamp 3 (pic. 3.1–3), remove the hose and drain the coolant into the sump.
Loosen clamp 2, remove the hose, move it down and drain the coolant from the radiator.
Disconnect the air duct mount 1 from the generator.
Pic. 3.1–4. Location of the oil filter and oil heat exchanger: 1 - hose; 2 - oil filter; 3 - oil heat exchanger
Disconnect the additional coolant hose at the bottom of the oil heat exchanger and drain the coolant into a sump. On fig. 3.1-4 the arrow shows the clamp for attaching the additional hose of the cooling system to the oil heat exchanger.
Pic. 3.1–5. Location of the coolant drain plug from the engine block
Turn out from the block of cylinders of the engine a carving stopper of drain of a cooling liquid shown on fig. 3.1-5 arrow.
When installing the plug, a new sealing ring must be used.
Pic. 3.1–41. Location of engine cover screws
Remove the four screws and remove the engine cover (see fig. 3.1–41).
Pic. 3.1–42. Location of the clamps for fastening the air pipe of the air flow meter and the suction pipeline: 1 - fuel supply pipeline; 2 - fuel supply hose
Loosen the clamps and remove the air pipe connecting the air flow meter and the suction pipe (see fig. 3.1–42).
Warning: The fuel system is under pressure. Before disconnecting the elements of the fuel system, it is necessary to relieve the pressure in the system. To do this, cover the fuel system disconnection point with a clean rag and, being careful, slowly unscrew the connecting nut.
Unscrew the nuts and disconnect the fuel supply hose from the pipeline (see fig. 3.1–42).
Pic. 3.1–6. The location of the hoses in the upper part of the engine: 1 - crankcase ventilation hose; 2, 4, 6, 7 - vacuum hoses; 3 - valve for switching the suction pipeline; 5 - connection of a vacuum hose with a vacuum brake booster; 8 - screws for fastening the air pipe of the throttle assembly
Disconnect the crankcase ventilation hose from the right cylinder head cover (pic. 3.1–6).
Unscrew the valve 3 for switching the suction line and take it to the side together with the line.
Carefully remove vacuum hose 6.
Turn out screws 8 and remove an air branch pipe from the body of a throttle knot.
Disconnect the crankcase ventilation hose from the left cylinder head cover.
Remove the vacuum brake booster hose from the connector and remove the connector from the bracket.
Pic. 3.1–7. Location of protective covers (1–4) at the rear of the engine compartment
Remove protective covers 1-4 at the rear of the engine compartment (pic. 3.1–7).
Pic. 3.1–8. Screw location and removal direction (1) control box cover
Rotate the left cover covering the control box in the direction of the arrow (1, fig. 3.1–8), and remove the rear right screw.
Turn out the remained screws of fastening shown by arrows on fig. 3.1–8.
Remove the control box cover.
Pic. 3.1–9. Location of the engine control unit (1), drive control unit (2) and electrical connectors (3) on the bulkhead of the engine compartment
Disconnect the electrical connectors from the engine control unit 1 (pic. 3.1–9) and drive control unit 2, as well as all electrical connectors on the bulkhead of the engine compartment. The arrows indicate the location of the screws securing the fuse box.
Disconnect the electrical connector from the GRA control unit.
Remove the sealing plate located between the engine compartment and the radiator reservoir.
Release from clips electroconducting in a motor compartment.
Turn away plugs of fastening of an electrical wiring to a partition of a motor compartment and move an electrical wiring aside.
Pic. 3.1–10. Air outlet location (1) and air intake (2) near the front of the engine
Separate air intake 2 (pic. 3.1–10) from the front cross member and remove it together with the air pipe 1.
Pic. 3.1–11. The location of the screws securing the upper part of the air filter housing
Turn out four screws shown by arrows in fig. 3.1-11, fastening the upper part of the air filter housing, while disconnecting the electrical connectors 1-3 and take them to the side.
Pic. 3.1–12. Arrangement of a connecting nut of fastening of the delivery pipeline of the hydraulic pump
Unscrew the union nut and disconnect the hydraulic pump discharge pipe (pic. 3.1–12).
Pic. 3.1–13. Location of the clamp for attaching the vacuum hose to the AKF valve
Loosen the clamp and disconnect the vacuum hose from the AKF valve (pic. 3.1–13).
Vehicles with GRA
Pic. 3.1–14. Control rod location (1), fastening nuts (2) vacuum block and vacuum hose (3)
Disconnect control rod 1 (pic. 3.1–14) from the vacuum block.
Remove the vacuum hose 3 from the vacuum block.
Unscrew nut 2 and remove the vacuum block.
All cars
Pic. 3.1–15. Attachment points for the accelerator cable to the throttle valve and the accelerator cable sheath to the bracket
Disconnect the accelerator cable from the throttle, remove the cable sheath from the bracket (pic. 3.1–15).
Pic. 3.1–16. An arrangement of collars of fastening of hoses of system of cooling to a broad tank (arrows on the right) and to the heater fittings (arrows on the left) on the bulkhead of the engine compartment
Loosen the clamps and disconnect the hoses connecting the middle pipe of the cooling system and the expansion tank (arrows on the right in Fig. 3.1–16).
Loosen the clamps (arrows on the left) and disconnect the coolant hoses going to the heater.
Move the hoses to the lower right side of the engine compartment.
Pic. 3.1–17. Direction of movement of the electrical connector lock
Disconnect all electrical connectors on the front wall by moving the latch in the direction of the arrow (pic. 3.1–17).
Disconnect the electrical connectors of the lambda sensors and remove the wires going to the lambda sensors from the clamps.
Unclip all electrical wiring from the engine.
Vehicles with manual transmission
Disconnect the electrical connector from the speedometer sensor (arrow A in fig. 3.1–18).
Pic. 3.1–18. Location of the electrical connectors of the speedometer sensor (A) and reverse switch (IN)
Disconnect the electrical connector from the reverse switch - multifunction sensor (arrow IN).
All cars
Unscrew the nuts of fastening of a final collector and a reception exhaust pipe accessible from above.
Turn out, but not completely, the upper bolts of fastening of a transmission to the engine.
Pic. 3.1–19. Fastening elements of the middle pipe of the cooling system: 1, 3 - clamps; 2, 5 - bolts; 4 - hose
Remove the middle pipe of the cooling system, for which loosen the clamps 1 and 3 (pic. 3.1–19), unscrew the fastening bolts 2 and 5 and disconnect the hose 4 from it.
Vehicles with electric radiator fan
Turn out screws, remove the electric fan of a radiator and take away it together with the connected wires aside.
Vehicles with a viscous radiator fan
Unscrew the fan shroud and remove it.
Pic. 3.1–40. Removing the radiator fan bolt
Holding the radiator fan pulley from turning with a special key 3212, unscrew the pulley mounting bolt with a regular key. Since the bolt has a left-hand thread, it must be turned clockwise to loosen it (see fig. 3.1–40).
Lift up the radiator fan and remove it from the vehicle.
All cars
Pic. 3.1–43. Arrangement of screws of fastening of a casing of a v-ribbed belt
Loosen the screws and remove the V-ribbed belt cover (see fig. 3.1–43).
Pic. 3.1–20. Installing a special tool (1) for attaching the fuel supply hose to the hydraulic pump
Using a special tool (pic. 3.1–20), connect the fuel supply hose to the hydraulic pump. In the left lower part of the engine compartment, loosen the clamp and remove the bolt securing the fuel supply hose bracket.
Move the tool down between the toothed belt guard and the cylinder head or cylinder block.
Place a clean rag under the hydraulic pump to catch any escaping oil.
Vehicles with manual transmission
Pic. 3.1–21. Fastening elements of wires and connectors: 1 - wire fastening bolt «masses»; 2 - wire fastening nut; 3 - electrical connector; 4 - collar
Release the lock and disconnect the electrical connector 3 (pic. 3.1–21).
Remove the cover covering the electrical connections.
Remove the bolt 1 of the wire «masses».
Turn away nuts 2 fastenings of wires.
Turn away a collar 4 fastenings of electric wires and take away wires aside.
Vehicles with air conditioning and/or automatic transmission
Warning: Mark the direction of rotation of the V-ribbed belt with chalk, marker or paint. If the V-ribbed belt rotates in the opposite direction during installation, this will lead to its destruction.
Pic. 3.1–44. Loosening the tension of the V-ribbed belt: 1, 2 - the location of the pins for fixing the tension mechanism. The arrow shows the direction of rotation of the hex key to reduce the tension of the V-ribbed belt
Using a 10 mm hex wrench, loosen the tension of the V-ribbed belt by turning the tensioner clockwise until the holes are aligned (arrows 1 and 2, see fig. 3.1–44).
Lock the tensioner in this position by inserting a 5 mm diameter steel rod into the holes.
Remove the V-ribbed belt from the pulleys.
Cars with air conditioning
To collect oil, install a pan under the engine compartment.
Drain engine oil, by unscrewing the oil drain plug and, if necessary, pressing down on it to prevent the oil from escaping prematurely.
Unscrew the oil filter 2 (see fig. 3.1–4).
Loosen the clamp and remove the rear hose from the oil heat exchanger.
Remove the oil heat exchanger.
Warning: Do not open the cooling circuit of the air conditioning system.
Remove the A/C compressor electrical wires from the mountings.
Pic. 3.1–22. Arrangement of bolts of fastening of an arm of the compressor of the conditioner
Turn away four bolts of fastening of an arm of the compressor of the conditioner shown by shooters on fig. 3.1–22.
Take aside the air conditioning compressor along with the wires and tubes attached to it.
Vehicles with automatic transmission
Disconnect the electrical wires from the generator.
Pic. 3.1–23. Generator fastening elements: 1 - nut; 2 - bolt
Remove bottom bolt 2 (pic. 3.1–23) generator mounts.
While holding the top bolt from turning with a wrench, unscrew the nut 1.
Remove the top alternator mounting bolt and remove the alternator.
Pic. 3.1–24. Arrangement of bolts of fastening of a starter: 1 – a nut; 2 - electrical connector
Disconnect from a starter an electric socket 2 (pic. 3.1–24), unscrew nut 1 and disconnect from power starter («positive») the wire.
Remove two screws (arrows in fig. 3.1–24) starter mountings and, being careful, remove the starter.
Pic. 3.1–25. Location of torque converter mounting bolt
Through the hole opened after removing the starter, unscrew the three bolts securing the torque converter (pic. 3.1–25). To access each subsequent bolt, it is necessary to turn the engine crankshaft in the direction of its working rotation by 1/3 of a turn. To rotate the crankshaft, you must use the central bolt of the crankshaft pulley.
Pic. 3.1–26. Arrangement of bolts of fastening of the brackets supporting pipelines to an automatic transmission
Loosen two screws (pic. 3.1–26) attaching pipe support brackets to automatic transmission.
Pic. 3.1–27. Location of the engine speed sensor (1), electrical connector (2), speedometer sensor and bolt (3) fastenings of the pipeline of an automatic transmission
Unscrew engine speed sender 1 G28 if present. Sensor 1 (pic. 3.1–27) located on the front left side of the gearbox.
Note: Maintain cleanliness when working on an automatic transmission.
If necessary, remove the automatic transmission and drive shafts.
Pic. 3.1–28. Arrangement of nuts of fastening of a reception exhaust pipe to the forward muffler
From the bottom of the car, unscrew the nuts that secure the front exhaust pipe to the front muffler (pic. 3.1–28).
Pic. 3.1–29. An arrangement of nuts of fastening of couplings of system of release of the fulfilled gases
Unscrew the nuts indicated by the arrows in fig. 3.1–29, fastening couplings.
Carefully remove the front exhaust pipe with catalytic converter and lambda sensors. Do not damage the wires going to the lambda sensors.
Pic. 3.1–30. Location of the engine torque compensator support: 1 - support; 2 - limiter
Turn out bolts of fastening of a support 1 (pic. 3.1–30) motor torque compensator and move the support to remove it.
From the bottom of the car, unscrew the accessible bolts securing the gearbox to the engine.
Pic. 3.1–31. The location of the engine mounting bolts to the lower frame
Remove the bottom bolts (pic. 3.1–31) fastening the engine to the lower frame.
Prepare a 10-222A/4 left adapter and a 10-222A hoist with claws to support the gearbox.
Drill a hole with a diameter of 10.2 mm from the back side on the top platform of the adapter 10-222A / 4 and cut the M12 thread.
Pic. 3.1–32. Installation of devices for supporting the gearbox: 1 - left adapter 10-222A / 4; 2 - lifting device 10-222A; 3 - set of grippers 2024 A/2, 2024 A/1 and 3147
Install adapter 10-222A/4 and lifting device 10-222A on the racks and connect them together using the threaded hole (pic. 3.1–32).
The lifting screw must be located at the rear of the lifting device.
Attach the load handler to the gearbox.
Turn the lifting device screw to tension the catch so that the weight of the gearbox is supported by the lifting device. Completely remove the lower gearbox-to-engine bolts.
Disconnect the hood support struts from the hood. Install the hood vertically and secure it in this position.
Pic. 3.1–33. Engine mounting with lifting clamp 3033: 1 - clamp
Hang lifting clamp 3033 on the hoist (pic. 3.1–33) and attach it to the engine.
Turn out the top bolts of fastening of a transmission to the engine.
Make sure all electrical wires, hoses, fittings and pipes are disconnected from the engine.
Vehicles with automatic transmission
Pic. 3.1–34. Using a pry bar to hold the torque converter against the engine when removing the engine
Before removing the engine, press the torque converter against the engine with a pry bar (pic. 3.1–34).
Being careful, lift the engine, then take it away from the gearbox and remove it up from the engine compartment.
Vehicles with automatic transmission
Attach the torque converter to the engine.
Installation
The engine is installed in the reverse order of removal, taking into account the following.
Replace with new self-locking nuts and bolts that have been tightened to a certain angle, as well as o-rings and gaskets.
Check for the presence of centering sleeves that determine the relative position of the engine and gearbox.
When connecting the engine to the transmission, be careful not to damage the engine speed sensor.
Pic. 3.1–35. Using the special tool VW 540 (1) when installing the engine on the stand
If you need to repair the engine, fix it on the stand using the special tool VW 540 (pic. 3.1–35).
Vehicles with manual transmission
Clean the splines of the drive shaft and, when reusing the clutch disc, remove traces of corrosion from it. Lubricate the splines of the drive shaft with a thin layer of grease G 000 100.
Check the condition of the clutch release bearing and replace it if necessary.
Using a drift, check the centering of the clutch disc.
Check the condition of the needle bearing at the end of the crankshaft on the flywheel side. Replace bearing if necessary.
Vehicles with automatic transmission
To attach the torque converter to the drive plate, bolts of the original design must be used.
Pic. 3.1–36. Measuring the distance between the bearing surface for the torque converter mounting bolts and the bearing surface of the crankcase
Check the correct installation of the torque converter. If the distance between the bearing surface for the torque converter mounting bolts and the surface of the crankcase is 19 mm, then the torque converter is installed correctly. With an incorrectly installed torque converter, this distance is 14 mm (pic. 3.1–36). Improper installation of the torque converter leads to the destruction of the leading part of the torque converter and the automatic transmission pump.
Reinstall the engine and rock it from side to side to ensure it is properly supported on its supports.
Install poly V-belt.
Check that the engine torque compensator support is installed correctly.
If the flywheel was removed, move the engine speed sensor aside when installing the engine.
Check accelerator cable adjustment.
Fill the cooling system with coolant. Coolant must not be reused if the cylinder head has been removed or the cylinder block has been replaced.
Fill the power steering system with oil and bleed air from it.
Pour into the engine engine oil.
Make sure that the elements of the exhaust systems are correctly installed on the suspensions and do not touch the body when rocking.
Check that the electrical connectors are connected correctly.
Connect wire «masses» to the battery.
Turn on the radio and enter the code into it.
Raise the windows with the power windows up to the stop. Then press all power window switches again for at least 1 second to the closed position to activate the power window control unit.
Set the time on the clock.
Before starting the engine, check the presence and level of oil in the engine.
Pic. 3.1–37. The location and numbering of the bolts for fastening the mechanical gearbox to the engine: A - the location of the centering sleeve
Pic. 3.1–38. The location and numbering of the bolts for fastening the automatic transmission to the engine: A, B - the location of the centering bushings
Pic. 3.1–39. Poly V-belt driven units: 1 - vibration damper; 2 - bolt, 22 Nm; 3 - V-ribbed belt; 4 - bolt, 22 Nm; 5 - generator; 6 - bolt, 45 Nm; 7 - bolt, 22 Nm; 8 - generator bracket; 9 - bolt, 45 Nm; 10 - spacer sleeve; 11 - bolt, 55 Nm; 12 - bolt, 22 Nm; 13 – a pulley of the pump of the amplifier of a steering; 14 – a delivery pipeline of the amplifier of a steering; 15 - hollow bolt, 40 Nm; 16 - sealing rings; 17 - bolt, 22 Nm; 18 – the pump of the amplifier of a steering with an arm; 19 - bolt, 22 Nm; 20 - poly V-belt tensioning mechanism; 21 - bolt, 25 Nm; 22 - air conditioner compressor; 23 - special nut, 25 Nm; 24 - V-ribbed belt pulley
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