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Home >> Volkswagen >> 1984 >> Vanagon Base, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 6 (1.6L 4-CYL Diesel/Turbo Diesel) >> Engine, Cylinder Head & Manifolds >> Engine >> Removal (All Except Quantum & Vanagon)

Removal (All Except Quantum & Vanagon)

WARNING: This page is about a different car, the 1983 Volkswagen Vanagon, 1983 Volkswagen Rabbit, 1983 Volkswagen Quantum, 1983 Volkswagen Pickup, and 1983 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect battery ground. Open coolant expansion tank. Open heater valve and drain all coolant from system at thermostat flange (engine cool). Remove radiator with fan. Remove alternator and detach fuel filter from body.
    NOTE: Never drain coolant while engine is hot. Doing so could cause engine block or cylinder head to warp.
  2. Disconnect wires for fuel shut-off solenoid, glow plugs, oil pressure switch and coolant temperature sensor. Disconnect hoses for heater and expansion tank. Remove fuel supply and return lines and disconnect accelerator cable with bracket from injection pump. Disconnect cold start cable.
  3. On air conditioned vehicles, remove air conditioner compressor and mounting brackets and set out of way without disconnecting hoses. On all models, disconnect wires from starter and back-up light switch and ground from transmission mount. On manual transmission models, detach clutch cable and remove relay shaft lever.
  4. Remove exhaust flex pipe nuts or spring clips. Disconnect drive shafts from drive flanges. Remove starter, horn, oil filter and front engine mount. Remove axle nuts (vehicle must be on ground) and disconnect lower ball joints from bearing housings. Remove drive shaft while holding strut assembly away from vehicle.
  5. Reconnect ball joints so vehicle may be lowered onto wheels. Remove complete rear mount. Remove right front wheel. Attach sling (US 1105) to engine and lift slightly. On manual transmission models, remove relay shaft and gearshift lever rods.
  6. On all models, remove bolts holding side mounts to body. Lower engine and transmission assembly to dolly. Raise vehicle to clear and remove assembly.
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