Removal and installation of the power unit (VW Passat B4)

Remove the battery. Open the expansion tank cap. Disconnect the hoses from the radiator and drain the coolant. Drain the oil from the engine oil sump. Remove the air filter assembly with the air supply hose and vacuum hose. Unscrew the lower radiator grille mounting bolt, detach the grille mounting latches near the bolt and pull the trim forward. Remove the radiator grille. Disconnect the wires from the headlights. Remove the radiator mounting bracket. Disconnect the drive cable from the hood lock and remove it from the radiator grille. Unscrew the two radiator grille mounting bolts located in front under the headlights, lift and remove the radiator grille with the headlights. Disconnect the cooling system hoses connecting the radiator to the cylinder head, to the water pump and the expansion tank (disconnect from the engine or tank). Disconnect the connectors of the electric fan wires and its switch. Raise the radiator assembly with the bracket for fastening the electric fan with the electric fan and guide casings. Disconnect the wires from the generator, the oil pressure warning lamp sensor, the intake manifold heating thermal relay, the carburetor starting device cover thermal relay, as well as the ignition coil wire, the reversing light switch connector and connectors of other units and sensors, depending on the configuration. On cars with a carburetor engine, disconnect the fuel supply and drain hoses from the fuel pump. On cars with a fuel injection system, disconnect the fuel supply and drain hoses from the fuel pressure regulator. Disconnect the throttle drive cable. Disconnect the jumper connection to the ground and the flexible speedometer drive shaft from the gearbox. Remove the starter. Disconnect the cooling system hoses from the cylinder head. Disconnect the clutch cable or disconnect the clutch release slave cylinder from the clutch housing and hang the cylinder from the body without disconnecting the pipe going to the clutch release master cylinder.

Loosen the transmission mount support bolt. Remove the receiver, disconnect the vacuum hose from the brake booster. Remove the rear subframe from the engine mount support by loosening the three mounting bolts. Disconnect the front wheel drive shafts from the transmission as described in subsection "Front wheel drive", and hang them with hooks to the body. Disconnect the exhaust manifold from the muffler inlet pipe. Disconnect the gear shift drive rod or gear selection cable, as indicated in the relevant subsections. Install a lifting device and sling the engine. Remove the engine and gearbox mount supports (Fig. 2-1). Raise the engine and gearbox assembly and remove them from the engine compartment upwards Install the power unit on a workbench and disconnect the gearbox from the engine.