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3.2. Removal and installation of the engine

Recommendations about removal of the engine
Before work attentively study this section.
If the engine is removed for repair, it is necessary to choose the place for work, to provide space for service and storage of spare parts. Repairs are recommended to be made at car repair shop or in a garage with an equal horizontal floor with a pure hard coating.
Before removal clear of pollution and wash up the engine and a motor compartment. For removal of the engine use the load-lifting mechanism allowing to lift safely the power unit.
If you remove the engine for the first time, it is necessary to invite the skilled expert. Some works should be performed with the assistant.
All clips and collars which at removal of the engine will be damaged or cut at assembly of the engine replace new.
The engine is removed without transmission forward.
The merged cooling liquid needs to be collected and utilized.
Before a detachment of the rechargeable battery find out whether you have a code of turning on of the radio receiver.

Removal
Switch off ignition and disconnect a wire of "weight" from the rechargeable battery.
Uncover a broad tank.
Fig. 3.1-1. Arrangement of clamps of fastening of the lower mudguard of a motor compartment

Release the clamps shown by shooters in fig. 3.1-1 and remove the lower mudguard of a motor compartment.
Fig. 3.1-2. Arrangement of bolts of fastening of an arm of the lower mudguard of a motor compartment

Turn off two bolts and remove an arm of the lower mudguard of a motor compartment (fig. 3.1-2)
Install under the engine the pallet for collecting cooling liquid.
Fig. 3.1-3. Arrangement of an air duct (1) and collars (2 and 3) of fastening of hoses of the cooling system

Weaken a collar of 3 (fig. 3.1-3), remove a hose and merge cooling liquid in the pallet.
Weaken a collar 2, remove a hose, move it down and merge cooling liquid from a radiator.
Disconnect fastening of an air duct 1 from the generator.
Fig. 3.1-4. Arrangement of an oil filter and oil heat exchanger: 1 – hose; 2 – oil filter; 3 – oil heat exchanger

Disconnect an additional hose of the cooling system in the lower part of the oil heat exchanger and merge cooling liquid in the pallet. In fig. 3.1-4 the arrow showed a collar of fastening of an additional hose of the cooling system to the oil heat exchanger.
Fig. 3.1-5. An arrangement of a stopper of discharge of cooling liquid from the block of cylinders of the engine

Turn out the carving stopper of discharge of cooling liquid shown in fig. 3.1-5 by an arrow from the block of cylinders of the engine.
At installation of a stopper it is necessary to use a new sealing ring.
Fig. 3.1-41. Arrangement of screws of fastening of a casing of the engine

Turn out four screws and remove an engine casing (see fig. 3.1-41).
Fig. 3.1-42. An arrangement of collars of fastening of an air branch pipe of a flowmeter of air and the soaking-up pipeline: 1 – fuel supply pipeline; 2 – fuel supply hose

Weaken collars and remove the air branch pipe which is connecting the measuring instrument of a consumption of air and soaking up the pipeline (see fig. 3.1-42).

Prevention
The fuel system is under pressure. Before separation of elements of fuel system it is necessary to take off pressure in system. For this purpose close the place of separation of fuel system pure rags and, being careful, smoothly unscrew a connecting nut.
Unscrew nuts and disconnect a fuel feeding hose from the pipeline (see fig. 3.1-42).
Fig. 3.1-6. An arrangement of hoses in the top part of the engine: 1 – hose of ventilation of a case; 2, 4, 6, 7 – vacuum hoses; 3 – the valve for switching of the soaking-up pipeline; 5 – connection of a vacuum hose with the vacuum amplifier of brakes; 8 – screws of fastening of an air branch pipe of throttle knot

Disconnect a hose of system of ventilation of a case from the right cover of a head of the block of cylinders (fig. 3.1-6).
Turn out the valve 3 for switching of the soaking-up pipeline and take him together with the pipeline aside.
Being careful, remove a vacuum hose 6.
Turn out screws 8 and remove an air branch pipe from the case of throttle knot.
Disconnect a hose of system of ventilation of a case from the left cover of a head of the block of cylinders.
Remove a hose of the vacuum amplifier of brakes from a connector and take a connector from an arm.
Fig. 3.1-7. An arrangement of protection covers (1-4) in a back part of a motor compartment

Remove protection covers 1-4 in a back part of a motor compartment (fig. 3.1-7).
Fig. 3.1-8. Arrangement of screws and direction of removal (1) of a casing of the control unit

Turn the left casing closing the control unit in the direction specified by an arrow (1, fig. 3.1-8), and turn out the back right screw.
Turn out the remained fastening screws shown by shooters in fig. 3.1-8.
Remove a control unit casing.
Fig. 3.1-9. An arrangement of the control unit of the engine (1), the control unit of the drive (2) and electric sockets (3) on a partition of a motor compartment



Disconnect electric sockets from the control unit of the engine 1 (fig. 3.1-9) and the control unit of the drive 2, and also all electric sockets on a partition of a motor compartment. Shooters specified an arrangement of screws of fastening of the case of safety locks.
Disconnect the electric socket from the GRA control unit.
Take the sealing plate located between a motor compartment and a tank of a radiator.
Release from clips an electrical wiring in a motor compartment.
Unscrew plugs of fastening of an electrical wiring to a partition of a motor compartment and move an electrical wiring aside.
Fig. 3.1-10. An arrangement of an air branch pipe (1) and an air inlet (2) about a forward cross-piece of the engine

Separate an air inlet of 2 (fig. 3.1-10) from a forward cross-piece and remove it together with an air branch pipe 1.
Fig. 3.1-11. Arrangement of screws of fastening of the top part of the case of the air filter

Turn out four screws shown by shooters in fig. 3.1-11, fastenings of the top part of the case of the air filter, at the same time disconnect electric sockets 1-3 and take them aside.
Fig. 3.1-12. Arrangement of a connecting nut of fastening of the delivery pipeline of the hydraulic pump

Unscrew a connecting nut and disconnect the delivery pipeline of the hydraulic pump (fig. 3.1-12).
Fig. 3.1-13. An arrangement of a collar of fastening of a vacuum hose to the AKF valve

Weaken a collar and disconnect a vacuum hose from the AKF valve (fig. 3.1-13).

Cars with GRA
Fig. 3.1-14. Arrangement of draft of management (1), nut of fastening (2) of the vacuum block and vacuum hose (3)

Disconnect draft of management 1 (fig. 3.1-14) from the vacuum block.
Remove from the vacuum block a vacuum hose 3.
Unscrew a nut 2 and remove the vacuum block.

All cars
Fig. 3.1-15. Places of fastening of a cable of an accelerator to a butterfly valve and accelerator cable covers to an arm

Disconnect an accelerator cable from a butterfly valve, take a cover of a cable from an arm (fig. 3.1-15).
Fig. 3.1-16. An arrangement of collars of fastening of hoses of the cooling system to a broad tank (shooters on the right) and to heater unions (shooters at the left) on a partition of a motor compartment

Weaken collars and disconnect the hoses connecting an average pipe of the cooling system and a broad tank (arrows on the right in fig. 3.1-16).
Weaken collars (arrows at the left) and disconnect the cooling system hoses going to a heater.
Move hoses to the right lower part of a motor compartment.
Fig. 3.1-17. Direction of movement of a clamp of the electric socket

Disconnect all electric sockets on a forward wall for what move a clamp in the direction of an arrow (fig. 3.1-17).
Disconnect electric sockets a lambda sensors and take from wire clamps, going to a lambda sensors.
Release all electric conducting of the engine from clamps.

Cars with the mechanical transmission
Disconnect the electric socket from the speedometer sensor (an arrow A in fig. 3.1-18).
Fig. 3.1-18. An arrangement of electric sockets of the sensor of a speedometer (A) and the switch of a backing (In)

Disconnect the electric socket from the backing switch – the multipurpose sensor (arrow B).

All cars
Unscrew nuts of fastening of a final collector and a reception exhaust pipe available from above.
Turn out, but not completely, the top bolts of fastening of the transmission to the engine.
Fig. 3.1-19. Elements of fastening of an average pipe of the cooling system: 1, 3 – collars; 2, 5 – bolts; 4 – hose

Remove an average pipe of the cooling system for what weaken collars of 1 and 3 (fig. 3.1-19), turn out bolts of fastening 2 and 5 and disconnect from it a hose 4.

Cars with the electric fan of a radiator
Turn out screws, remove the electric fan of a radiator and take him together with the connected wires aside.

Cars with the radiator fan with the viscous coupling
Unscrew a casing of the fan and remove it.
Fig. 3.1-40. Reversing of a bolt of fastening of the fan of a radiator

Holding a radiator fan pulley from a provorachivaniye a special key 3212, a usual key unscrew a bolt of fastening of a pulley. As the bolt has the left carving, for unscrewing it is necessary to rotate it clockwise (see fig. 3.1-40).
Lift the fan of a radiator up and remove it from the car.

All cars
Fig. 3.1-43. Arrangement of screws of fastening of a casing of a poliklinovy belt

Turn out screws and remove a casing of a poliklinovy belt (see fig. 3.1-43).
Fig. 3.1-20. Installation of special device (1) for fastening of a hose of supply of fuel to the hydraulic pump

Using special adaptation (fig. 3.1-20), attach a hose of supply of fuel to the hydraulic pump. In the left lower part of a motor compartment weaken a collar and turn out a bolt of fastening of an arm of a hose of supply of fuel.
Move special adaptation between a casing of a gear belt and a head of the block of cylinders or the block of cylinders down.
Enclose pure rags under the hydraulic pump for collecting the following oil.

Cars with the mechanical transmission
Fig. 3.1-21. Elements of fastening of wires and sockets: 1 – bolt of fastening of a wire of "weight"; 2 – nut of fastening of a wire; 3 – electric socket; 4 – collar

Release a clamp and disconnect the electric socket 3 (fig. 3.1-21).
Remove the casing closing electric connections.
Turn off a bolt of 1 fastening of a wire of "weight".
Turn off nuts 2 fastenings of wires.
Turn off a collar 4 fastenings of electric wires and take wires aside.

Cars with the conditioner and / or the automatic transmission

Prevention
Chalk, marker or paint note the direction of rotation of a poliklinovy belt. If at installation poliklinovy the belt rotates in other party, it will lead to its destruction.
Fig. 3.1-44. Weakening of a tension of a poliklinovy belt: 1, 2 – installation sites of pins for fixing of the mechanism of a tension. The arrow showed the direction of rotation of a six-sided key for reduction of a tension of a poliklinovy belt

Using a face six-sided key on 10 mm, weaken a tension of a poliklinovy belt for what turn the tension mechanism clockwise before combination of openings (arrows 1 and 2, see fig. 3.1-44).
Fix the tension mechanism in this situation, having inserted a steel core with a diameter of 5 mm into openings.
Take off poliklinovy a belt from pulleys.

Cars with the conditioner
For collecting oil install the pallet under a motor compartment.
Merge engine oil, having unscrewed a stopper of a masloslivny opening and if necessary pressing it that oil did not follow prematurely.
Unscrew an oil filter 2 (see fig. 3.1-4).
Weaken a collar and remove a back hose from the oil heat exchanger.
Remove the oil heat exchanger.

Prevention
Not to open a contour of cooling of air conditioning system.

Take electric wires of the compressor of the conditioner from fastenings.
Fig. 3.1-22. Arrangement of bolts of fastening of an arm of the compressor of the conditioner

Turn off four bolts of fastening of an arm of the compressor of the conditioner shown by shooters in fig. 3.1-22.
Take aside the conditioner compressor together with the wires and tubes attached to it.

Cars with the automatic transmission
Disconnect electric wires from the generator.
Fig. 3.1-23. Elements of fastening of the generator: 1 – nut; 2 – bolt

Turn out the lower bolt of 2 (fig. 3.1-23) of fastening of the generator.
Holding a key the top bolt from a provorachivaniye, unscrew a nut 1.
Take the top bolt of fastening of the generator and remove the generator.
Fig. 3.1-24. Arrangement of bolts of fastening of a starter: 1 – nut; 2 – electric socket

Disconnect the electric socket 2 (fig. 3.1-24) from a starter, unscrew a nut 1 and disconnect a power ("plus") wire from a starter.
Turn out two bolts (arrows in fig. 3.1-24) fastenings of a starter and, being careful, remove a starter.
Fig. 3.1-25. Arrangement of a bolt of fastening of the hydrotransformer

Through the opening which opened after removal of a starter turn out three bolts of fastening of the hydrotransformer (fig. 3.1-25). For access to each subsequent bolt it is necessary to turn a bent shaft of the engine in the direction of its working rotation on 1/3 turns. For a provorachivaniye of a bent shaft it is necessary to use the central bolt of fastening of a pulley of a bent shaft.
Fig. 3.1-26. An arrangement of bolts of fastening of the arms supporting pipelines to the automatic transmission

Turn off two bolts (fig. 3.1-26) of fastening of arms for support of pipelines to the automatic transmission.
Fig. 3.1-27. Arrangement of the sensor of frequency of rotation of the engine (1), electric socket (2), sensor of a speedometer and bolt (3) fastenings of the pipeline of the automatic transmission

Unscrew the sensor of 1 frequency of rotation of the G28 engine at its existence. The sensor 1 (fig. 3.1-27) is located in a forward left part of the transmission.

Note
Observe purity during the work with the automatic transmission.

If necessary remove the automatic transmission and shaft of the drive.
Fig. 3.1-28. An arrangement of nuts of fastening of a reception exhaust pipe to the forward muffler

From below the car unscrew nuts of fastening of a reception exhaust pipe to the forward muffler (fig. 3.1-28).
Fig. 3.1-29. An arrangement of nuts of fastening of connecting couplings of system of production of the fulfilled gases

Unscrew the nuts specified by shooters fig. 3.1-29, the fixing connecting couplings.
Being careful, remove a forward exhaust pipe with catalytic converter and a lambda sensors. At the same time do not damage the wires going to a lambda sensors.
Fig. 3.1-30. Arrangement of a support of the compensator of torque of the engine: 1 – support; 2 – limiter

Turn out bolts of fastening of a support 1 (fig. 3.1-30) of the compensator of torque of the engine and, moving a support, remove it.
From below the car turn out available bolts of fastening of the transmission to the engine.
Fig. 3.1-31. An arrangement of bolts of fastening of the engine to the lower frame

Turn out the lower bolts (fig. 3.1-31) of fastening of the engine to the lower frame.
Prepare the left adapter 10-222A/4 and the load-lifting device 10-222A with captures for support of the transmission.
From the back party on the top platform of an adapter 10-222A/4 drill an opening with a diameter of 10,2 mm and cut M12 carving.
Fig. 3.1-32. Installation of devices for support of the transmission: 1 – left adapter 10-222A/4; 2 - load-lifting device 10-222A; 3 – set of captures of 2024 A/2, 2024 A/1 and 3147

Establish an adapter 10-222A/4 and the load-lifting device 10-222A on racks and connect them together, using a carving opening (fig. 3.1-32).
The screw of rise has to settle down from the back party of the load-lifting device.
Fix capture of the load-lifting device on the transmission.
Rotating the screw of the lifting device, pull capture so that the weight of the transmission was perceived by the lifting device. Completely turn out the lower bolts of fastening of the transmission to the engine.
Disconnect from a cowl of a rack of support of a cowl. Establish a cowl vertically and enshrine it in this provision.
Fig. 3.1-33. Fastening of the engine load-lifting capture 3033: 1 – capture

Suspend on таль load-lifting capture of 3033 (fig. 3.1-33) and fix it on the engine.
Turn out the top bolts of fastening of the transmission to the engine.
Make sure that all electric wires, hoses, branch pipes and pipelines are disconnected from the engine.

Cars with the automatic transmission
Fig. 3.1-34. Use of mount for pressing of the hydrotransformer to the engine at removal of the engine

Before removal of the engine press mount the hydrotransformer to the engine (fig. 3.1-34).
Being careful, raise the engine, then take away it from the transmission and take from a motor compartment up.

Cars with the automatic transmission
Fix the hydrotransformer on the engine.

Installation
Installation of the engine is carried out to the sequences, the return to removal, taking into account the following.
Replace with new samokontryashchiyesya of a nut and bolts which tightened a dovorachivaniye on a certain corner, and also sealing rings and laying.
Check existence of the aligning plugs defining relative position of the engine and transmission.
At connection of the engine with the transmission be careful not to damage the sensor of frequency of rotation of the engine.
Fig. 3.1-35. Use of the special VW 540 (1) tool at installation of the engine on the stand

If it is necessary to repair the engine, fix it at the stand by means of the special VW 540 tool (fig. 3.1-35).
Cars with the mechanical transmission
Clear vents of a shaft of the drive and at reuse of a clutch plate remove from it corrosion traces. Grease drive shaft vents with a thin layer of G 000 100 lubricant.
Check a condition of the bearing of switching off of coupling and if necessary replace it.
Using a mandrel, check centering of a clutch plate.
Check a condition of the needle bearing in an end face of a bent shaft from a flywheel. If necessary replace the bearing.

Cars with the automatic transmission
For fastening of the hydrotransformer to a drive plate it is necessary to use bolts of an original design.
Fig. 3.1-36. Measurement of distance between a basic surface for bolts of fastening of the hydrotransformer and a basic surface of a case

Check correctness of installation of the hydrotransformer. If the distance between a basic surface for bolts of fastening of the hydrotransformer and a surface of a case makes 19 mm, so the hydrotransformer is installed correctly. At incorrectly installed hydrotransformer this distance makes 14 mm (fig. 3.1-36). The wrong installation of the hydrotransformer leads to destruction of the leading part of the hydrotransformer and pump of the automatic transmission.
Install the engine into place and, having shaken it here and there, provide the correct arrangement on support.
Establish poliklinovy a belt.
Check correctness of installation of a support of the compensator of torque of the engine.
If the flywheel was removed, then at installation of the engine take aside the sensor of frequency of rotation of the engine.
Check adjustment of a cable of an accelerator.
Fill in cooling liquid in the cooling system. Reuse of cooling liquid is not allowed in case the head of the block of cylinders was removed or the block of cylinders was replaced.
Fill in oil in system of the amplifier of steering and remove from it air.
Fill in engine oil in the engine.
Make sure that elements of systems of production of the fulfilled gases are correctly established on suspension brackets and do not concern a body when rocking.
Check correctness of connection of electric sockets.
Connect a wire of "weight" to the rechargeable battery.
Turn on the radio receiver and enter into it a code.
Lift glasses power windows up to an emphasis. Then press all switches of a window regulator once again, at least for 1 second, in the provision of closing for activation of the control unit of window regulators.
Determine time on hours.
Before launch of the engine check existence and level of oil in the engine.
Fig. 3.1-37. An arrangement and numbering of bolts of fastening of the mechanical transmission to the engine: And – an installation site of the aligning plug

Fig. 3.1-38. An arrangement and numbering of bolts of fastening of the automatic transmission to the engine: And, In – installation sites of the aligning plugs

Fig. 3.1-39. The units put in action by a poliklinovy belt: 1 – quencher of fluctuations; 2 – bolt, 22 N · m; 3 – poliklinovy belt; 4 – bolt, 22 N · m; 5 – generator; 6 – bolt, 45 N · m; 7 – bolt, 22 N · m; 8 – generator arm; 9 – bolt, 45 N · m; 10 – expansion plug; 11 – bolt, 55 N · m; 12 – bolt, 22 N · m; 13 – pulley of the pump of the amplifier of steering; 14 – delivery pipeline of the amplifier of steering; 15 – hollow bolt, 40 N · m; 16 – sealing rings; 17 – bolt, 22 N · m; 18 – the pump of the amplifier of steering with an arm; 19 – bolt, 22 N · m; 20 – mechanism of a tension of a poliklinovy belt; 21 – bolt, 25 N · m; 22 – conditioner compressor; 23 – special nut, 25 N · m; 24 – pulley of a poliklinovy belt