2. Remove the engine chamber cover and place it in a safe place so that it does not get scratched.
3. Drain the engine coolant.
4. Place a suitable container under the engine, then unscrew the oil pan drain plug and drain the oil. Finally, clean the drain plug and screw it back. Replace the plug gasket every time the tube gasket is necessary.
5. Remove the radiator together with the cooling fan assembly.
6. For a carburetor engine, remove the air cleaner assembly, then disconnect the throttle cable near the carburetor. Move the cable to the side so it is out of the way.
7. Disconnect the electrical wires supplying the following equipment, mark each wire at the time of disconnection to avoid mistakes when connecting them:
- a) Alternating current generator.
- b) Oil pressure sensor on the cylinder head (photo 1.9).
- c) Mixture heater in the drive manifold.
- d) Radiator fan thermal switch.
- d) Ignition device (high and low voltage wires).
- e) Single joint on the automatic choke cover.
- g) Coolant temperature sensor.
- c) Ground wire near the gearbox and multi-function switch on the gearbox (if any).
- i) Starter.
Wires can be marked using adhesive tape with inscribed markings.
8. Disconnect the flexible fuel hose from the fuel pump, as well as the return hose (to the fuel tank), clamp or plug the pipes to prevent fuel from leaking.
9. Disconnect the heater elastic hoses from the engine.
10. In the model with a manual transmission, disconnect the clutch cable.
11. Disconnect the following wires located near the carburetor, mark them at the time of disconnection to avoid mistakes during connection:
- a) Thermal-time valve.
- b) Idle speed control valve.
- c) Joint of the mixture heater in the drive manifold.
- d) Joint of the partial throttle opening channel heater.
12. Disconnect the speedometer cable from the gearbox.
13. Disconnect and remove the pressure relief tank, if present.
14. Disconnect the flexible hoses from the servo system and drive manifold.
15. Loosen and remove the gearbox suspension bolt.
16. Raise and support the vehicle, providing sufficient space to work underneath.
17. Disconnect the control rods from the gearbox.
18. On automatic transmission models, remove P (Park), then disconnect the throttle and selector cables from the transmission.
19. Disconnect the drive axles from the gearbox as described in Section 7 and hang them so that they do not interfere.
20. To disconnect the exhaust manifold from the exhaust pipe, a special spring clamp puller is required. Although it is possible to disconnect the exhaust pipe without a device, installing the clamps is only possible using a special puller.
The information is available on the website vwmanual.ru
21. Now you can lower the car, since the rest of the disassembly steps are performed from above.
22. Using a jack or winch, slightly raise the engine and gearbox assembly.
23. Unscrew the three bolts 2 of the rear engine mount bracket (figure 1.13).
24. Unscrew and remove bolt 1 (figure 1.12) front engine mount bracket. Loosen bolt 1 (figure 1.13) transmission mount bracket. Further raising, lowering or rotating of the engine and transmission assembly may be necessary.
25. The engine and gearbox assembly is ready to be removed. Beforehand, it is necessary to check whether all cables, wires and elastic hoses are disconnected.
26. Removing the engine assembly to the gearbox requires the assistance of a second person who will not allow the engine to damage other components around it while it is being removed. The assembly must be rotated slightly while being removed. After removal from the vehicle, place the drive assembly on the ground or in a location where further disassembly will take place.
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