Bolted connections must be unscrewed from below on the body. To do this, put the car on the goats using a mobile lift. Before starting work in the engine compartment, the wings of the body must be protected by covers.
Depending on the year of manufacture of the vehicle and its equipment, electrical wires, low pressure hoses and coolant hoses may be routed differently. Pre-mark each of the removed wires and hoses with adhesive tape.
Withdrawal
Disconnect ground cable from battery
Drain coolant, disconnect hoses from coolant pump.
Remove radiator.
Attention: If the hoses are fastened with clamping clamps, cut the clamps with side cutters. When installing, use new clamping clamps.
Remove the air filter and cover the carburetor with something to avoid getting foreign objects into it.
Remove the coolant hoses from the cylinder head and from the exhaust manifold.
Disconnect the vacuum hoses at the intake manifold and carburetor. For easier installation, mark the hoses with adhesive tape.
Disconnect the gas supply, do not remove the retainer.
Disconnect the cold start wire
Mark the fuel lines on the sump with tape, disconnect them and plug them with suitable plugs. To do this, you can use clean bolts of the desired diameter.
Disconnect plug connections for intake manifold heater and idle air shutoff valve. Loosen the cable ties on the cylinder head cover.
Disconnect the electrical wire and brown vacuum line from the control valve on the carburetor.
Mark and disconnect the electrical wires from the temperature sensor, oil pressure gauge switches, and the generator.
Raise the car with a jack.
Remove the bottom cover of the engine compartment. Unscrew front silencer pipe at exhaust manifold and gearbox holder. Slightly lower the exhaust system and hang it on a wire.
Unscrew the clutch slave cylinder from the gearbox and set aside without opening the hydraulic system.
Attention: do not unscrew the tube.
Vehicles with power steering (servo control)
Remove the V-belt, remove the hydraulic pump and set aside or hang it on a wire to the body. The holders remain screwed to the engine block.
Caution: If air enters the hydraulic system, it must be bled after installation.
Cars with air conditioning
Loosen and remove the compressor drive V-belt.
Loosen the screws securing the compressor and hang it to the side of the body with the pipes connected.
Attention: Do not open the coolant circuit of the air conditioner.
5 cylinder engine
Remove bumper.
Unscrew the middle bumper support.
Unscrew the cross member from below.
Diesel engine
Unscrew the direct and return fuel lines on the high pressure fuel pump (injection pump).
Disconnect the electrical wires from the fuel cut-off valve and glow plugs.
Unscrew the exhaust pipe from the exhaust manifold.
Remove starter.
Clamp the gearbox with V.A.G.-10 cross member 222A and 3147. To do this, insert clamp 3147 into the upper hole in the gearbox motor mount.
Attention. If there is no VAG cross member, place a hoist with a wooden pad under the gearbox and raise the gearbox slightly.
Position the cross member as shown in the illustration, hooking it onto the special lugs -arrows-. Pulley side: 3rd hole in the bar in position 3. Handwheel side: 3rd hole in the bar in position 3. Secure the pins with cotter pins. The figure shows a 4-cylinder engine. With a 5-cylinder engine: on the belt pulley side, the 1st hole of the bar in position 3, on the flywheel side, the 4th hole of the bar in position 8.
Attention: To match the center of gravity, the hook bars must be correctly set in length and height. The yoke side labeled 1-4 faces the belt pulley. The hole in the slats is counted from the beginning of the hooks.
If there is no crossbar for lifting, attach a suitable chain to the special earrings.
Raise the engine with a crane until the engine mounts are unloaded.
Tighten the gearbox lifting tool.
Unscrew the engine mounts on the left and right by unscrewing the self-locking nuts.
Unscrew the front engine brackets.
Loosen the bolts connecting the engine-gearbox.
Unscrew flywheel cover.
Press the engine out of the gearbox with a pry bar.
Attention: On vehicles with automatic transmission, first unscrew the torque converter, mounted on 3 bolts, and its safety lock from the driven disk.
Check that all drives and hoses from the engine to the body are disconnected. Then take out the engine.
Attention: Raise the engine carefully to avoid damage to the body.
Installation
Check engine mounts, coolant hoses, oil and fuel hoses for porosity and cracks. If necessary, replace.
Check the clutch disc for sufficient thickness of the friction linings and check their condition. In case of progressive wear of the pads or high mileage, replace the clutch. If the clutch release bearing makes noise when the clutch pedal is depressed, the bearing must be replaced.
Clean and lubricate with a thin film of MoS2 grease, the clutch switch bearing and the gearing of the gearbox input shaft.
Caution: Do not lubricate the clutch release bearing guide bush.
Check whether there are bushings in the cylinder block for centering the engine and gearbox. Insert bushings if necessary.
Put the gasket on the bushings and fix it with grease at several points on the cylinder block.
Carefully lower the engine into the engine compartment. Take care not to damage the input shaft of the gearbox, clutch and body.
Install without tightening the new self-locking nuts on the engine mounts.
Tighten the bolts connecting the engine and gearbox.
Screw on flywheel cover with 10 Nm.
Screw the engine brackets to 25 Nm.
With a rocking motion, land the engine without voltage. Then tighten the engine mounts to 35 Nm.
5-cylinder engine: Screw down cross member from below. Screw on the middle part of the bumper. Install the front bumper.
Screw the exhaust pipe of the muffler on the manifold with 30 Nm, on the gearbox holder with 25 Nm.
Install starter.
Install and tighten the cooling compressor and power steering pump mounting bolts, if removed. The tightening torques are as follows: compressor supports to the cylinder block, M8 bolts - 25 Nm; bolts M10 - 30 Nm; pump - 20 Nm. Put on and tighten the V-belt.
Install the lower engine compartment cover.
Lower the car.
Connect the electrical wires for the intake manifold heater and the idle air shutoff valve.
Install electrical wire and brown vacuum line to control valve
Install the vacuum hoses to the intake manifold and carburetor as marked. If you need to fix the clamps.
Connect the gas supply.
Connect the cold start drive and adjust.
Install the fuel lines on the sump in accordance with the marked marks and secure with clamps.
Connect the electrical wires to the temperature sensor, the oil pressure switch to the generator.
Install all cooling system hoses and secure with clamps.
Check that all electrical wires, vacuum pipes, cooling system circuits and fuel hoses are connected in accordance with the markings. Fix the electrical wires with cable ties.
Install the radiator.
Diesel engine:
Screw the direct and return fuel lines to the high pressure fuel pump. Do not mix up the hollow bolts. The fuel line return bolt is marked on the hex head "OUT". Reverse connection leads to the following problems: insufficient engine power, foggy exhaust at full load, maximum speed is not reached, the engine idles unevenly.
Adjust the cold start control actuator.
Connect the electrical wires to the fuel cut-off valve and glow plugs.
Check when the high pressure fuel pump starts to flow.
Check the oil level in the engine and gearbox.
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