Removal (5000)

Disconnect battery ground cable. Remove coolant expansion tank cap. Disconnect hose from bottom of expansion tank and drain. Place temperature lever in "COLD" position if vehicle is equipped with air conditioning.
Disconnect coolant hoses and drain coolant. DO NOT disconnect any fuel lines. Remove control pressure regulator, cold start valve, and fuel injectors. Loosen air duct and vacuum hoses from throttle valve assembly. Remove air cleaner cover with filter.
Pull hood latch cable guide from bracket. Remove radiator cowl, shroud, electric fan and radiator, if necessary for clearance. On air conditioned vehicles, remove grille and tilt condenser outward.
Remove power steering pump, leaving hoses connected. Remove vacuum amplifier, ignition coil and EGR control valve. Remove windshield washer and power steering reservoirs from holders. Remove distributor cap, rotor and ignition wires.
Remove circlip to remove throttle cable (manual transmission). Remove throttle push rod (automatic transmission). Disconnect electrical connections on distributor. Disconnect wiring to oil pressure and water temperature senders.
Remove air conditioning compressor, leaving hoses connected. Tie back compressor with wire. Remove exhaust pipe from manifold and from transmission bracket. Remove front engine mount, starter and alternator.
Remove torque converter mounting bolts (automatic transmission) from drive plate, doing so through starter mounting hole. Remove lower engine-to-transmission bolts. Install transmission support tool (VW 785/1). Remove upper engine-to-transmission bolts.
Remove left engine bracket and loosen right engine bracket from engine mount. With engine lifting device securely attached, lift engine until "V" belt pulley is behind grille opening. Lift transmission with support tool. Detach engine from transmission.
Lift engine upward, turning front of engine toward right as engine is lifted. Remove engine, using care that all wires, hoses and vacuum lines are free. Mount engine on stand (VW 540).