REMOVAL & INSTALLATION
Figures 1 through 6
The Volkswagen engine is mounted on the transaxle, which in turn is attached to the frame. In the Type 1 and 2 models, there are two bolts and two studs attaching the engine to the transaxle. Type 3 engines have an extra mounting at the rear of the engine. Type 3 engines with automatic transaxle have front and rear engine and transaxle mounts. At the front, the gearbox is supported by the rear tubular crossmember; at the rear, a crossmember is bolted to the crankcase and mounted to the body at either end.
When removing the engine from the car, it is recommended that the rear of the car be about 4 ft. off the ground. Remove the engine by bringing it out from underneath the car. Proceed with the following steps to remove the engine.
An easy way to prevent hooking up your automatic choke wire to the distributor and vice versa when installing the engine is to take the time to mark each wire and the terminal to which it is connected with masking tape, then coding each two pieces of tape 1, 2, 3, etc. When hooking up the wiring, simply match the pieces of tape. Or you can draw a diagram indicating the wire colors and the components to which they attach. Do the same with all vacuum hoses and you should have no problems installing the engine.
- Disconnect the battery ground cable.
- Disconnect the generator wiring.
- Remove the air cleaner. On Type 1 and Type 2 engines, remove the rear engine cover plate. On Type 2/1600 cc engines, remove the rear crossmember.
Disconnect the throttle cable and remove the electrical connections to the automatic choke, coil, electromagnetic cut-off-jet, the oil pressure sending unit, the backup light wiring at the right of the engine (Type 1), and all other interfering wiring.Removing the throttle cable on the upright fan engine includes:
- Disconnecting the throttle cable from the carburetor;
- Removing the spring retainer, the spring cover and the spring;
- Pulling the cable out from the transaxle side of the engine and;
- Removing the cable guide.
- Disconnect the fuel hose at the front engine cover plate and seal it to prevent leakage.
- On Type 3 models, remove the oil dipstick and the rubber boot between the oil filter and the body.
- Remove the cooling air intake bellows on Type 3 engines after loosening the clip that secures the unit.
- On Type 3 models, remove the warm air hose.
- On Type 3 fuel injected engines, remove and plug the pressure line to the left fuel distributor pipe and to the return line on the pressure regulator. Disconnect the fuel injection wiring harness.
- Raise the car and support it with jackstands.
- Remove the flexible air hoses between the engine and heat exchangers, disconnect the heater flap cables, remove the electrical heater fan hoses, if equipped, unscrew the two lower engine mounting nuts, and slide a jack under the engine. On Type 2 engines, remove the two bolts from the rubber engine mounts located next to the muffler.
- On Type 1 Automatic Stick Shift models, disconnect the control valve cable and the manifold vacuum hoses. Disconnect the ATF suction line and plug it. On Type 3 fully automatic transaxle models, disconnect the vacuum hose and the kick-down cable.
- On all Automatic Stick Shift and fully automatic models, remove the four bolts from the converter drive plate through the holes in the transaxle case. After the engine is removed, hold the torque converter on the transaxle input shaft by using a strap bolted to the bellhousing.
- Raise the jack until it just contacts the engine and have an assistant hold the two upper mounting bolts so that the nuts can be removed from the bottom. 1971 Type 2s have only an upper right-hand mount bolt.
1972 and later Type 2s have two top engine-to-transaxle bolts which also serve as top carrier bolts for the transaxle. The transaxle must be supported when these bolts are removed to prevent damage which could be caused by letting the unit hang. Many later model Type 1 and Type 2 vehicles have a captive left side top engine-to-transaxle nut which is reached from the transaxle side of the unit.
- When the engine mounts are disconnected and there are no remaining cables or wires left to be disconnected, move the engine toward the back of the car so that the clutch or converter plate disengages from the transaxle.
- Lower the engine out of the car.
Installation is the reverse of the above. When the engine is lifted into position, the crankshaft should be rotated using the generator pulley so that the clutch plate hub will engage the transaxle shaft splines. Tighten the upper mounting bolts first. Check the clutch, pressure plate, throwout bearing, and pilot bearing for wear.
On Type 3, synthetic washers are used to raise the engine about 3mm when the rear engine mounting is attached and tightened. Use only enough washers in the rear mount so that the engine is lifted no more than 3mm. Care should be used when installing the rear intake housing bellows of the Type 3 engine.
- Disconnect the battery.
- Remove the cooling air bellows, warm air hoses, cooling air intake duct, and air cleaner. On sedans, remove the cooling air fan. On station wagons, remove the dipstick tube rubber boot and the dipstick.
- Disconnect the fuel injection wiring.
- Disconnect the coil wires and remove the coil and its bracket.
- Disconnect the oil pressure switch and the alternator wiring.
- Disconnect the vacuum hose for the intake air distributor.
- Disconnect the accelerator cable.
- Working through the access hole at the upper right corner of the flywheel housing, remove the three screws which secure the torque converter to the drive plate. Remove the ATF oil dipstick and the rubber boot.
- Remove the two upper engine mounting bolts. Jack up the car and, working beneath the car, remove the muffler shield and the heat exchanger.
- Disconnect the starter wiring.
- Remove the heater booster exhaust pipe.
- Remove the two lower engine mounting nuts.
- Jack up the engine slightly and remove the four engine carrier screws.
Do not loosen the mountings on the body or the engine transaxle assembly will have to be recentralized in the chassis.
- Remove the engine from the car.
- Reverse the removal procedures to install the engine. Install the engine on the lower engine mounting studs and then locate the engine in the engine carrier. When installing the engine in the carrier, lift the engine up so that the four screws are at the top of the elongated holes and tighten them in this position. If it is necessary to raise or lower the engine for adjustment purposes, use the threaded shaft. After the engine is installed, make sure that the rubber buffer is centered in the rear axle carrier. Make sure that the engine carrier is vertical and parallel to the engine fan housing. Readjust it if necessary by moving the brackets on the side members.