Removal and installation the engine (VW Beetle)

Removal

To remove the engine, the car must be raised at the rear by approximately 1 m and supported using reliable supports.



Raise the rear seat and disconnect the ground terminal from the battery.



Disconnect the air ducts from air filter 2 and unscrew the bolts securing it from below. Remove the filter and cover the carburetor with a clean, lint-free cloth.

Disconnect electrical wires 3 from the generator, ignition coil, automatic starter, idle speed control solenoid valve and oil pressure sensor.

Disconnect accelerator rod 4 from the carburetor and remove the guide tube from the fan housing.

Caution! Do not lose the mounting sleeve!

Unscrew nuts 5 from the two upper bolts 3* of the fan. In this case, the assistant must hold the bolts.



Raise the vehicle and place it on supports.



Release the spring clamp on the heating air duct 6 and disconnect the air duct. Disconnect the left and right heating rods 7.



Disconnect fuel hose 8 and plug it with a wooden plug.

Unscrew the engine mounting bolts 9 at the top left.

Pull the accelerator rod out of the guide tube.

Place a jack under the engine crankcase and slightly raise the engine.



Loosen nuts 11 of the lower engine mounting bolts.


Move the engine away from the gearbox and lower it down, being careful not to damage the input shaft and clutch disc.

Installation

Before installing the engine, thoroughly clean the gearbox housing and the engine flywheel housing (do not clean the clutch release bearing with gasoline or any other means!).

Check the clutch release bearing for wear and replace if necessary. 2 based paste to the plastic ring.

Lubricate the starter shaft bushings with a small amount of grease.

MoS₂ based paste to the splines of the gearbox input shaft.

Note: To check or center the clutch disc, see. chapter "Clutch".

Engage 1st gear so that the input shaft of the gearbox cannot turn.

Install the engine on the lift. The engine can also be installed using a thick board approximately 50 cm wide. In this case, at least two assistants will be required for lifting.

Give the assistant the command to lift the engine and at the same time direct it from above into the engine compartment. The unit must be installed with great care to avoid damaging the clutch disc, clutch release bearing and gearbox input shaft. Slide the engine onto the gearbox while turning the V-belt pulley to turn the crankshaft and insert the input shaft into the clutch disc.

Caution! Before connecting the engine to the gearbox, insert the accelerator cable into the fan housing guide pipe.

Press the engine against the gearbox, insert the upper engine mount bolts and tighten them, then do the same with the lower bolts.

Connect the heater ducts and air damper rod.

Connect the fuel hose.

Check the operation of the clutch (see chapter "Clutch").

Lower the vehicle and connect the electrical wires.

Slide the accelerator cable guide tube into the fan housing and tighten the mounting sleeve. Connect the accelerator cable (see section "Replacing the accelerator cable").

Install the air filter.

Check the oil level in the engine oil sump.

Adjust the ignition (see section "Ignition system").