2.2. Removal and installation of the engine

4-CYLINDER PETROL ENGINE

The engine is removed without transmission down. For removal of the engine the jack is necessary for the engine or a factory machine jack.

The machine jack and four props is necessary for installation of the machine on props.

Depending on year of construction and equipment of a wire, vacuum hoses or hoses of cooling liquid can have various arrangement. Therefore it is recommended to mark before removal the corresponding pipelines an adhesive tape. All removed or cut-off cable connections after installation of the engine have to be fixed on the same place.

Removal

PERFORMANCE ORDER
1. To disconnect a wire of "weight" (-) from the rechargeable battery.
Prevention

Before shutdown of a wire of "mass" of the accumulator, be convinced that ignition is switched off!

Do not forget that at shutdown of "weight" from memory the code of the anti-theft device and the fixed settings of the radio receiver are erased!
2. To install the car on props (see subsection 1.18).
3. To cast away a radiator. For this purpose to unscrew screws of fastening (1) at the left and on the right.
4. To cast away a radiator and a support of the lock forward.
5. To remove the lower mudguard of a motor compartment.
6. To separate system of removal of the fulfilled gases between an exhaust collector and a forward exhaust pipe (cm. subsection 2.19.1).
7. To merge cooling liquid (see subsection 2.16.3).
8. To disconnect from the engine the top hose of a radiator on the union of cooling liquid the lower hose on the oil heater a hose on the case of the thermostat of cooling liquid the lower pipe of cooling liquid of a water pomp two hoses of a broad tank and the heat exchanger on a pipe of cooling liquid, previously having squeezed pincers collars and having shifted them back.
9. To take out pins (are specified by shooters) from expansion clips on the right and at the left and to take out expansion clip-on earrings from radiator arms.
10. To remove a radiator (see subsection 2.16.2.1).
11. To disconnect all electrical wiring from the engine:
      – the potentiometer plug WITH;
      – plug of a potentiometer of a butterfly valve;
      – the plug of multicontact connection of the injecting valves;
      – idling stabilization valve plug;
      – the plug of the sensor of Hall on the ignition distributor;
      – shtekerny connection a lambda probe, from below cars, on an arm of hinged units on the right;
      – pressure sensor plug on the steering amplifier (if is available);
      – two plugs of otdatchik of temperature of cooling liquid;
      – plugs from the oil pressure sensor from above on the oil heater and on the left face side of a head of the block of cylinders;
      – a wire of "weight" from a cover of a head of the block of cylinders;
      – to disconnect a thick wire (V) and a thin blue wire (Р) on the generator.
12. To remove a plait of wires from the engine, having marked the former provision of cable clips with felt-tip pens. Clips to open or cut.
13. To uncover the ignition distributor, to remove all candle wires and together to put everything aside.
14. To remove a drive rope from a butterfly valve and from an emphasis (see subsection 2.17.5).
15. To remove an air hose in junctions between the air filter and the case of a butterfly valve, to unscrew and take out the valve of stabilization of idling together with an arm, to remove a hose of ventilation of a case of the engine, to remove a hose of stabilization of idling from the case of the air filter and to take out an air hose together with the idling stabilization valve.
16. To remove all vacuum hoses from the engine:
      – on a butterfly valve of heating of reception air;
      – on the magnetic valve of a tank with absorbent carbon;
      – Digifant monitor;
      – on the backpressure valve of the amplifier of brakes.
17. To remove the fuel supply pipeline (black) going to the valve of start of the cold engine and the distributor, and perepuskny the pipeline (blue) from the fuel distributor, having weakened collars. Before removal to enclose rags for collecting the following fuel. To stop up fuel-supply lines with suitable traffic jams. Hoses can be stopped up, for example, with pure screws of the corresponding diameter.
18. To take out from an opening on the transmission case a rubber stopper (it is specified by an arrow) and to fix the lever of switching off of coupling by an assembly pin or the M8x22 screw of mm.
19. At cars with the power steering to unscrew the pump together with an arm and to suspend on a wire to a body. Hoses can be not removed.
Prevention

Hoses cannot be bent. If hydraulic pipelines open, after assembly it is necessary to let out the air from system.
For the car with the conditioner
20. To weaken and remove maple a compressor belt (see subsection 2.12.1).
21. To unscrew the compressor together with an arm and to suspend together with pipelines aside to a body.
Prevention

The contour of circulation of coolant cannot be opened. Coolant at hit on skin can cause frostbites.
22. To screw on the block of cylinders in front under an arm of an oil filter (arrow) assembly VW 3230 adaptation. To tighten bolts the moment of 20 N · m.
23. To unscrew from below all bolts of fastening of the engine to the transmission.
24. To remove back support of the engine.
25. To place under assembly VW-3230 adaptation a jack for the engine and the V.A.G transmission. - 1383A and to raise the engine and the transmission until the bearing of the engine does not unload. If near at hand there is no V.A.G jack. - 1383A and assembly VW-3230 adaptation, it is possible to use a factory machine jack with wooden laying.
26. To unscrew on the right the central bolts of a support of the engine.
27. To remove on the right engine support.
28. To unscrew from above all bolts of fastening of the engine to the transmission and to separate the engine from the transmission.
29. By means of a jack it is careful to lower the engine.
Prevention

To lower the engine with big foresight in order to avoid its damages, and also the transmission and a body.

Installation

PERFORMANCE ORDER
1. To check engine support, fuel, oil pipelines and hoses of the cooling system for wear and lack of cuts, if necessary to replace.
2. To check thickness and a condition of frictional overlays of the conducted clutch plate. At strong wear or a big run to replace coupling completely. If when pressing a coupling pedal the bearing of switching off publishes noise, the bearing to replace.
3. To check wear of the bearing of switching off of coupling, if necessary to replace (see subsection 3.2).
4. To clear the bearing of switching off of coupling and a vent of a power shaft, to grease with a thin layer MoS2 lubricant, or V.A.G. - Fett G000100.
Prevention

Not to grease the directing plug of the bearing of switching off.
5. To check existence on the block of cylinders of the directing plugs for centering of the engine and the transmission, if necessary to establish.
6. To get an intermediate plate on the directing plugs and to grease in certain places with fatty lubricant, having pasted to the block of cylinders.
7. To carefully enter the engine into a motor compartment. To make a pull with big precautions in order to avoid damage of a power shaft, coupling or a body.
8. To screw new самоконтрящиеся nuts of support of the engine. Not to tighten a nut.
9. To attach the engine to the transmission, rotating at the same time a power shaft of a box so that it entered coupling and a flywheel. It is also possible to rotate the crankshaft for the central bolt.
10. To tighten connecting bolts of the engine to the transmission the following torques:
      – M8 bolts – 20 N · m;
      – M10 bolts – 60 N · m;
      – M12 bolts – 80 N · m.
11. To tighten a flywheel casing the moment of 20 N · m.
12. To install by strong musclemen without tension the engine. At last to tighten engine support the following torques:
      – an engine support on bearing M10 beam – 65 N · m;
      – engine support on the right at the block of cylinders of 50 N · m 90 ° (1/4 turns) in addition;
      – engine support behind at the block of M8 cylinders – 20 N · m;
      – engine support behind at the block of M10 cylinders – 45 N · m;
      – engine support behind at the M8 transmission – 20 N · m.
13. To unscrew assembly VW-3230 adaptation from the block of cylinders.
14. To put on the fuel supply pipeline (black) the union, and perepuskny the pipeline (blue) the fuel distributor, to fix by collars. Not to mix pipelines of giving and return of fuel.
15. If acted, then to screw the refrigerating compressor and the pump of the power steering. The power steering pump inhaling moment – 20 N · m. To put on and pull maple a belt (see subsection 2.12.1).
16. To take out an assembly pin or the M8x22 screw from the transmission case. To close an opening a rubber stopper and to check the correct provision of a press bar of the lever of switching off of coupling.
17. To fix without tension on a collector a forward exhaust pipe.
18. To establish a tube of cooling liquid between the thermostat and a water pomp, a hose of cooling liquid from a heater radiator.
19. To establish a radiator (see subsection 2.16.2.1).
20. To attach all hoses of cooling liquid, to fix by collars:
      – the top hose from a radiator on the union of cooling liquid;
      – the lower hose on the oil heater;
      – a hose on the case of the thermostat of cooling liquid; two hoses of a broad tank and a radiator of a heater on a pipe of cooling liquid.
21. To push an engine plait through an inlet collector.
22. It is reliable to connect, according to designations by an adhesive tape, plugs of the following electrical wires:
      – the potentiometer plug WITH;
      – plug of a potentiometer of a butterfly valve;
      – multicontact connection of the injecting valves;
      – idling stabilization valve plug;
      – plug of the valve of start of the cold engine;
      – the plug of the sensor of Hall on the ignition distributor;
      – shtekerny connection a lambda probe under car on an arm of hinged units, on the right;
      – pressure sensor plug on the power steering case if is available;
      – two plugs of both sensors of temperature of cooling liquid;
      – the oil pressure sensor plug from above on the oil heater and on the left face side of a head of the block of cylinders;
      – wire of mass of a cover of a head of the block of cylinders;
      – a thick wire (V) and a thin blue wire (R) of the generator to get a gray protective cap.
23. To fix electrical wires on former places by cable clips.
24. To establish the lower mudguard of a motor compartment (see subsection 2.4).
25. To lower the car.
26. To establish a cover of the distributor of ignition and to put on all wires spark plugs.
27. To establish an air hose together with the valve of stabilization of idling between the air filter and the case of a butterfly valve. To put on hoses and to fix by collars.
28. To screw the valve of stabilization of idling together with an arm on an inlet collector.
29. To establish a rope on a butterfly valve and on an emphasis, to adjust (cm. subsection 2.17.5).
30. To connect all vacuum hoses to the engine:
      – a hose of heating of reception air on a butterfly valve;
      – a hose of the magnetic valve of a tank with absorbent carbon on a butterfly valve;
      – a hose of the Digifant monitor on throttle a barrier;
      – a hose of the amplifier of brakes on the backpressure valve.
31. To check oil level in the engine and the transmission, if necessary to add.
32. To check concentration of cooling liquid, if necessary to add (see subsection 2.16.3).
33. To connect a wire of "weight" (-) to the rechargeable battery. To enter an anticreeping code, to program radio stations and to determine time on hours.
Prevention

To connect the battery only at the switched-off ignition, otherwise the control unit of system of injection of fuel will fail.
34. To warm up the engine up to the working temperature, again to check the level of oil, cooling liquid and tightness of connections.
35. To check the ignition moment (see subsection 2.14.6).
36. To check idling and maintenance WITH (see subsection 2.18.1).
37. To check adjustment of light of headlights (see subsection 10.19.4).