Removal and installation the engine (VW Passat B3)

The engine is removed with the gearbox from above. Therefore, before removing the engine, you should also read the chapter "Transmission". The exhaust and intake manifolds, as well as the carburetor and generator, are not removed from the engine. A crane is required to remove the engine. Under no circumstances should the engine be removed from below using a garage jack, as the jack can cause serious damage to the engine.

Since some connections need to be released from the underbody side, four stands are required, as well as a garage jack to lift the car. Before installation work in the engine compartment, the fenders must be covered with covers. The hood does not need to be removed before removing the engine.

Depending on the year of manufacture and equipment of the car, electrical wires, as well as vacuum hoses and coolant hoses, may be located in the engine compartment in different ways. Since it is impossible to choose each option separately, it is recommended to mark the corresponding wire with a tag before removing it.

Electrical plug connectors are usually secured with metal clips. Before disconnecting, press the clips or squeeze the side brackets.

Removal

Disconnect the battery ground (-) cable.

Remove the battery, see chapter "Electrical equipment system".

Remove the air intake hose from the air filter housing. Loosen the hose clamps beforehand.

Drain the coolant into a suitable container. To do this, remove the hoses from the coolant pump, see chapter "Cooling system".



Raise the car, see section "Lifting a car"

Unscrew the exhaust pipe from the exhaust manifold and the gearbox bracket. Lower the exhaust system slightly and suspend it with wire, see chapter "Exhaust system".

Cars with power steering

Loosen bolts -1- and "2" of the tensioner, remove the V-belt.

Unscrew the bolts "3" of the hydraulic pump bracket and, without disconnecting the pipelines, put the hydraulic pump aside or hang it on the body with a wire. Do not remove the pump bracket from the engine.

Caution: If the hydraulic hoses are disconnected, the system must be bled after installation, see chapter "Steering".

Cars with air conditioning

Loosen and remove the V-belt of the compressor and generator drive, see below in this chapter.

Unscrew the air conditioning compressor from the bracket and hang it on the side of the body with the pipes attached.

Caution: The coolant circulation system must not be opened. The coolant pipes are sensitive to bending, move the condenser carefully.

Disconnect the electrical wires from the headlights, fog lights and turn signal lights.



Loosen the hood lock mounting bolts "1" (arrows), remove the Bowden cable and the hood lock.


Vehicles with power steering: Loosen the clamp from the power steering fluid reservoir "2".

Remove the front bulkhead. To do this, unscrew the bolts "3" on both sides.



Remove the ventilation grille. To do this, unscrew the Phillips-head screws on the left and right. Fixing tabs "A" (from the back side) and press "B" with a screwdriver. Tilt the ventilation grille downwards.



Unscrew the mounting bolts (arrows) on both sides under the bumper.

Turbocharged diesel engine

Remove the U-shaped cover "1" from the charge air cooler air duct and remove the outer bolt through the mounting hole (arrow).

Lift the partition with the headlight slightly and carefully pull it forward.

Be careful not to damage the front edge of the wing.

Remove the coolant hoses from the cylinder head, coolant pump and expansion tank. At the same time, squeeze the clamps using a water pump clamp by the protrusions and loosen.

Caution: If the coolant hoses are secured with compression clamps, cut the clamps with side cutters and use clamps with a tightening screw during installation.

Remove the radiator complete with fan bracket, electric fan and air flow guides.

Carburetor engine

Remove the following wires or disconnect the plug connectors (see photo). Release the wires at the attachment points and place them on the body.

Note: To simplify subsequent connection, mark the wires with color tags and label them before disconnecting.

• 1 - generator
• 2 - hydraulic switch 1.8 bar
• 3 - intake manifold heater thermal switch
• 4 - starter cover thermal switch
• 5 - ignition wire (terminal 4)
• 6 - ignition distributor (terminal 1)

Remove fuel lines "A" and "B" and close the holes with suitable plugs.



Disconnect electrical wires:

• 2 - temperature indicator sensor
• 3 - hydraulic switch 0.3 bar
• 4 - gearbox ground wire
• 5 - plug from gearbox housing 6 - starter

Disconnect all wires and vacuum hoses from the carburetor.

Remove the gas rod from the carburetor and counter support, see chapter "Power supply system".

Engine with injection system

Remove or disconnect the following electrical wires:

• 1 - generator
• 2 - engine warm-up regulator at idle speed
• 3 - hydraulic switch 1.8 bar
• 4 - engine oil temperature sensor
• 5 - ignition wire (terminal 4 from ignition distributor)
• 6 - ignition distributor (terminal 1)
• 8 - coolant temperature sensor
• 10 - 0.3 bar hydraulic switch

Disconnect the ground wire on the cylinder head cover and the wire harness on the transmission mounting bracket.

Disconnect the electrical wires from the starter.

Remove the gas rod, see chapter "Petrol injection system".

Diesel engine

Disconnect the supply and return fuel lines from the high-pressure fuel pump.

Disconnect the electrical wires from the fuel switch and glow plugs.

All engines

Unscrew the speedometer drive shaft from the gearbox and close the hole with a cap.

Depending on the gearbox version, remove the clutch cable or unscrew the clutch slave cylinder from the gearbox and put it aside with the wires connected, see chapter "Clutch".

Disconnect the ground wire from the gearbox.



Loosen the cable rods "A" and "B" of the gear shift drive and the cable rod counter-supports on the gearbox.

Unscrew the cardan shafts from the gearbox and hang them on the body using wire hooks, see chapter "Front axle".



The VAG-2024A lifting device must be inserted properly into the engine lifting eyes (arrows), Belt pulley side: the second hole of the tire in position 1; flywheel side: third hole of the tire in position 7; secure your fingers with safety earrings.

Note: To adjust the center of gravity of the unit, the lifting hook tires must be correctly installed in the specified positions. The described positions 1-4 of the lifting beam are located on the belt pulley side. The holes in the tires are measured from the hook.

Using a crane, lift the engine so as to relieve the load on its supports.

If there is no suspension device, you can insert a suitable chain into the engine's lifting eyes, pass a suitable pipe through it, lift the engine slightly and support the pipe on the trestles.



Remove 3 bolts "A" at the right engine support "B".



Remove the hexagon head bolt "C" from the gearbox support "D".

Caution: On vehicles with brake booster, carefully push the hydraulic lines to the side to gain access to the bolt. On vehicles with anti-lock braking system, remove the coolant expansion tank if necessary.

Loosen nut "A" of the front retaining console "B".

Check if all hoses and wires from the engine to the body have been removed. Then remove the engine together with the gearbox.

Caution: When removing the engine, drive it carefully to avoid damaging the body.

Separate the engine from the gearbox by removing the partition at the flange of the cardan shaft. Unscrew the bolts securing the engine/gearbox and the partition to the gearbox housing

Installation

Check engine mounts, coolant, oil and fuel hoses for porosity and cracks, replace them with new ones if necessary.

Check the thickness and condition of the clutch drive disc linings. If the wear limit is reached or the vehicle has a high mileage, replace the clutch as a set. If the clutch release bearing makes noise when the clutch pedal is pressed, replace the bearing.

Clean the clutch release bearing and the splined engagement of the drive shaft and lightly lubricate with MoS₂ grease.

Check if the crankcase housing has bushings for centering the engine and gearbox; if not, insert the bushings.

Place the intermediate plate on the centering bushings and secure it to the engine crankcase at several points with a small amount of grease.

Carefully lower the engine into the engine compartment. When lowering the engine, do so carefully so as not to damage the drive shaft, clutch and body.

Tighten the engine mount with new self-locking nuts, but do not tighten them too much.

Perform assembly in reverse order. Tighten the engine and gearbox connecting bolts to the following torques: M10 bolts - 60 Nm; m12 bolts - 80 Nm. Tightening torques for engines with ABN, EZ, RF and PG designations: M10 bolts - 45 Nm; m12 bolts - torque 55 Nm.

Carefully insert the engine with the gearbox into the engine compartment. When lowering, make sure that the cardan shafts and body are not damaged.

When tightening the power unit supports, it is essential to maintain the sequence and prescribed tightening torque values. Lubricate the threads and mating surfaces of the heads of the unscrewed bolts with engine oil before installation.

4-cylinder engine (except 16-valve) up to 9/93

First tighten bolt "a" of the rear engine support bracket to 25 Nm, then bolt "e" of the gearbox support bracket to 60 Nm. Tighten bolt "c" to 60 Nm.



Tighten the front engine support "1". Tightening torques: e = 60 Nm, f = 70 Nm.

Note: Tightening torques for engines manufactured since 10/93, see below.

Loosen the rubber-metal support of the engine bracket and console, align it with shaking movements without tension and tighten it again, see the next chapter.

Attach the gear shift cable to the gearbox and adjust, see chapter "Gear shifter".

Screw the speedometer shaft to the gearbox.

Attach and adjust the clutch drive rod or tighten the clutch slave cylinder, see chapter "Clutch".

Tighten the front exhaust pipe to the exhaust manifold with a torque of 40 Nm and to the gearbox bracket with a torque of 25 Nm. Install the front bulkhead and radiator grille, see chapter "Body". 9 If removed, then screw on the air conditioning compressor and the power steering pump. Tightening torques: compressor bracket to the cylinder block, M8 bolts - tighten to 35 Nm; m10 bolts - tighten to 30 Nm; tighten the connecting bolts of the booster pump to a torque of 20 Nm. Apply the V-belt and tighten it, see below in this chapter.

Lower the car.

Connect the vacuum hoses to the intake manifold and carburetor as marked. If necessary, secure them with screw-tightening clamps.

Attach and adjust the throttle linkage, see chapters "Power supply system" and "Petrol injection system".

Connect the fuel lines in accordance with the markings and secure them with clamps.

Connect the electrical wires to the carburetor, temperature sensor, hydraulic switch and generator. Make sure that each plug is secured and the clamp is in the correct position.

Install the coolant hoses and secure them with clamps.

Check that all electrical wires, vacuum hoses, and coolant and fuel hoses are connected in accordance with the markings provided. Secure the hoses with clamps. Fix the electrical wires with tie clamps.

Install the radiator, see chapter "Cooling system".

Diesel engine

Screw the supply and return fuel lines to the fuel pump. Do not screw the hollow bolts in places, as they have different holes. The return fuel line mounting bolt has the "OUT" marking on the hex head. Incorrectly installed bolts may cause the following complaints: unsatisfactory engine power; foggy smoke on exhaust at full load; maximum crankshaft speed is not reached; the engine runs unsteadily at idle.

Adjust the cold start rod of the engine, see chapter "Diesel engine".

Connect the electrical wires to the fuel switch and glow plugs.

Check the start of fuel supply, see chapter "Diesel engine".

Check the oil level in the engine and gearbox, top up if necessary.

Check the concentration of antifreeze in the coolant and top up if necessary, see chapter "Cooling system".

Install the air filter. Clean the housing and filter and replace the filter element if necessary, see chapters "Power supply system" and "Petrol injection system".

Install and connect the battery.

Check the ignition timing, adjust if necessary, see chapter "Ignition system".

Check idle speed, adjust if necessary.

Warm up the engine to normal operating temperature, check the oil and coolant levels again, and check all hose connections for leaks.

Check the headlight adjustment and correct if necessary.

Engine and gearbox alignment

Alignment is necessary if the engine and gearbox have been removed and the metal supports of the front axle beam and engine bracket have been loosened.



Until 9/93 (except 16-valve engine): loosen the central bolt securing the rubber-metal support "A" (engine support).

16-valve engines from 12/88 to 9/93: instead of the right rubber-metal support (engine support) the hydraulic support is installed. To align the engine and gearbox, it is necessary to loosen the hydraulic support fastening to the front axle beam. The tightening torque of the hydraulic support on the front axle beam is 60 Nm; engine consoles to the engine and hydraulic support - 25 Nm.

From 10/93: Loosen the central engine mount bolt and also the fastening to the front axle beam.

Release the rubber-metal bearing (gearbox support) "B" at the gearbox and front axle beam.



Release the front engine mount at the engine mount bracket and console.

Use shaking movements to align the power unit without stress.

First tighten the bolts of support "A" to the prescribed torque value, and then tighten the bolts of support "B", see Fig. 10-959.

Engine Mount Tightening Torques from 10/93

Tightening torques are given for lubricated bolts. Values in brackets apply to 6-cylinder engines.



Front supports:
A - 55 Nm (60 Nm)
B - 55 Nm (60 Nm)
C - 50 Nm (55 Nm)

Rear supports on the left (step gearbox):
G — 50 Nm (60 Nm)
H - 25 Nm (25 Nm)
I — 30 Nm (25 Nm)

Rear supports on the right:
D—25 Nm (60 Nm)
E - 50 Nm (60 Nm)
F — 25 Nm (25 Nm)

Rear supports on the left (automatic transmission):
J — 60 Nm
K - 25 Nm
L — 30 Nm

Note: Different mounts for AAM and ABS engines.

Tightening torque of the front supports: nut A - 60 Nm, bolt C (short) - 35 Nm, bolt C (long) - 70 Nm.

Rear right supports: bolts E - 25 Nm, bolt A (in figure 10-959) — 80 Nm, engine support in the lower picture — 60 Nm.