NOTE The engine acts in film together with a transmission down.

ATTENTION Toplivoprovod is under pressure. to avoid traumas and hit on skin, put on goggles and gloves. Before separation of hoses wrap up a junction rags. Then dump pressure, accurately weakening connections.

Preliminary actions

To provide a free prokruchivaniye of the driveshaft, establish the selector lever in the situation "N".

Not to allow wheel blocking, leave a key in the ignition lock.

Before the beginning of dismantle of the power unit it is recommended to remove forward wheels. At the expense of it the car can be lowered on the lift, leaving between casings of brake disks and a floor some centimeters. Thus, at work optimum reach of all components in a motor compartment will be provided.

To avoid damages of the removed details, it is necessary to use the container for the removed details of V.A.G 1698.

Some components in this car it is impossible or it is heavy to dismantle, without removing the engine. Therefore before removal of the engine it is necessary to define all faulty details and after removal of the engine to replace them.

Switch off ignition and all electric consumers.

Disconnect the storage battery under a seat of the driver.

Removal of the power unit with a transmission assembled

Remove the left and right leads of a screen wiper. Remove a cowl sealant from a forward wall.

Fig. 2.19 . Fastening of covers of a water taking away box

To remove covers of A, B and C in a motor compartment and the D water taking away box (fig. 2.19) .

Fig. 2.20 . V.A.G adapters

Fasten the V.A.G 1318/20-1 adapter to the V.A.G 1318/20 adapter (fig. 2.20) .

Turn the gate (on T-shaped))))))))) counter-clockwise and open it completely.

ATTENTION Before depressurization of fuel system connect pumping-out VAS 5226 adaptation and dump pressure.

Turn off a protective cover of the air valve.

Connect to the air valve 1 the V.A.G 1318/20 adapter with the V.A.G 1318/20-1 adapter and the pumping-out VAS 5226 adaptation.

Fig. 2.21 . System depressurization

Twist the gate (on T-shaped))))))))) clockwise against the stop in the air valve (fig. 2.21) .

After a sbrasyvaniye of pressure of fuel it is possible to depressurize fuel system.

Under a junction in addition enclose rags for absorption of following fuel.

Fig. 2.22 . A detachment submitting топливопровода

Disconnect submitting топливопровод (fig. 2.22) .

After installation of the engine it is necessary to establish again in the same places all collars of cables which are removed or cut off at its dismantle.

Fig. 2.23 . Separation of the ventilating highway

Separate the ventilating highway to the electromagnetic valve of 1 absorber of N80 in a motor compartment (fig. 2.23) .

Fig. 2.24 . A tip detachment from the control unit of the engine and shutdown of a wire of weight of a plait of conducting

Disconnect the small tip A from the control unit of the engine and disconnect wires of weight of a plait of conducting (fig. 2.24) .

Fig. 2.25 . Shtekernye of connection

Open a cover of the block of safety locks, at the left in a water taking away box and disconnect shtekerny connections of A, B and C (fig. 2.25) .

Take a plait of wires from a water taking away box and put it on the engine.

Fig. 2.26 . Connection of wires of a starter and generator

Disconnect wires of a starter of A and the generator B and to put them on the engine (fig. 2.26) .

Disconnect vacuum hoses 1–3 from an inlet collector.

Fig. 2.27 . Connections of vacuum hoses

On cars with an alphabetic reference of the BAA engine in addition remove a vacuum hose 4 from an inlet collector (fig. 2.27) .

Fig. 2.28 . Connections of a hose of the pump of secondary air

Disconnect a hose from the pump of secondary air (fig. 2.28) .

Fig. 2.29 . Shtekernye sockets lambda probes

To disconnect tips 1-4 a lambda probes and to put tips on the engine (fig. 2.29) .

Cylinders 1-3: the black.

Cylinders 4-6: the brown.

Fig. 2.30 . Pipeline connection to the pneumosuspension bracket compressor

To disconnect the pipeline to the pneumosuspension bracket compressor from the air filter (the shooter in drawing 2.30 ) way described below.

Fig. 2.31 . Lock and tightening rings

Accurately hook a green lock ring 1 screw-driver. Then press on a tightening ring 2 in the arrow direction in drawing 2.31 .

After that disconnect the weakened highway of B from A branch pipe on the air filter.

Remove the top part of the air filter up. Unblock and disconnect the pipeline of ventilation of a case of a transmission from the case of the air filter.

Pump out a coolant from the conditioner.

ATTENTION When opening a broad tank it can leave hot steam. to avoid a travmirovaniye of eyes and an oshparivaniye, put on goggles and special clothes. Cover a cover of a bull-calf with rags and accurately unscrew it.

Merge cooling liquid. Disconnect the top hose from a radiator and the bottom hose from a radiator tube.

Fig. 2.32 . Fastening of a tube of a cooler of transmission oil

Disconnect tubes (the shooter in drawing 2.32 ) from a cooler of transmission oil below on the right. Put capacity under following oil.

Then disconnect the pipeline from an oil cooler for hydrosystems below at the left. Put capacity under following oil.

Release a double collar between catalytic converter and the intermediate exhaust silencer, and then shift a collar forward.

To Oboprita the main exhaust silencer on a rack for the engine and V.A.G 1383A transmission to turn off pendant fastenings of a back part of final system and lower it.

Remove a heat-shielding guard on the steering mechanism and weaken the kardanny hinge.

Fig. 2.33 . Sockets of a transmission and transfer case

Disconnect sockets A on a transmission and a transfer case of B and unhook draft of the selector (fig. 2.33)

Remove the back driveshaft. Remove forward wheels.

Remove forward podkrylka. Disconnect in a wheel niche brake pipelines from a brake hose and collect following brake liquid. Disconnect all shtekerny connections between a body and a forward axis in wheel niches.

Turn off pipelines of a pneumatic suspension bracket from a shock-absorber rack.

Fig. 2.34 . Transmission cross-piece

Remove a cross-piece of a transmission of A (fig. 2.34) .

Fig. 2.35 . Fixing of a rack of the shock-absorber

Fix racks of shock-absorbers how it is shown in drawing 2.35 , by means of the spring tightening VW 552 adaptation.

Turn off on each party of the car the top bolts on racks of shock-absorbers. Establish an assembly table for further works on engine removal.

Fig. 2.36 . Leading of racks of an assembly table under the power unit

Bring horizontally leveled assembly table under the power unit. 1 it is necessary at the left and to enter support on the right into the corresponding nests (fig. 2.36) .

Fig. 2.37 . Leading of support for the transmission console

At the same time enter the right and left support for the transmission console into the corresponding opening (fig. 2.37) .

When all four support are fixed in reception openings without pressing, unscrew both plates of conductors with a small tension under suspension bracket levers so that it was possible to remove the spring tightening VW 552 adaptation suspended for an insurance.

Fig. 2.38 . Installation of support under a stretcher

Enter support 2 into the corresponding nests in a stretcher, if necessary adjust height of support by means of a nut with a nakatka (fig. 2.38) .

Turn off bolts of a stretcher 1, 2 and 3, and also cross-pieces of a transmission 4.

NOTE After removal of a stretcher it is necessary to adjust corners of installation of wheels.

Slowly lower the power unit down, continuously supervising a free course.