Contents - Volkspage

2B.4 Engine removal and overhaul procedures
2.24 Separating the engine and
transmission
vehicle specification. Note that some of these
fixings also serve as mountings for the rear
engine mounting.
24 Starting at the bottom, remove all the
screws and nuts then carefully draw the
transmission away from the engine, resting it
securely on wooden blocks (see illustration).
Collect the locating dowels if they are loose
enough to be extracted.
Caution: Take care to prevent the
transmission from tilting, until the input
shaft is fully disengaged from the clutch
friction plate.
25 With reference to Chapter 6, remove the
clutch release mechanism, pressure plate and
friction plate.
Refitting
26 If the engine and transmission have not
been separated, proceed from paragraph 29
onwards.
27 Smear a quantity of high-melting-point
grease on the splines of the transmission
input shaft. Do not use an excessive amount
as there is the risk of contaminating the clutch
friction plate. Carefully offer up the
transmission to the cylinder block, guiding the
dowels into the mounting holes in cylinder
block.
28 Refit the bellhousing bolts and nuts, hand
tightening them to secure the transmission in
position. Note: Do not tighten them to force
the engine and transmission together. Ensure
that the bellhousing and cylinder block mating
faces will butt together evenly without
obstruction, before tightening the bolts and
nuts to their specified torque.
All models
29 With reference to Chapter 2A, refit the
rear engine mounting bracket and tighten the
retaining bolts to the specified torque.
30 Attach the jib of an engine hoist to the
lifting eyelets on the cylinder head and raise
the engine and transmission from the ground.
31 Wheel the hoist up to the front of the
vehicle and with the help of an assistant,
guide the engine and transmission in through
the top of the engine bay. Tilt the assembly
slightly so that the transmission casing enters
first, then guide the auxiliary belt drive pulleys
past the bodywork.
32 Align the engine mounting brackets with
the mounting points on the body - refer to
Chapter 2A for details. Insert the engine
mounting through-bolts, tightening them by
hand initially.
33 Detach the engine hoist jib from the lifting
eyelets.
34 Settle the engine and transmission
assembly on its mountings by rocking it
backwards and forwards, then tighten the
mounting through-bolts to the specified
torque.
35 Refer to Chapter 8 and reconnect the
driveshafts to the transmission.
36 The remainder of the refitting sequence is
the direct reverse of the removal procedure,
noting the following points:
a) Ensure that all sections of the wiring
harness follow their original routing; use
new cable-ties to secure the harness in
position, keeping it away from sources of
heat and abrasion.
b) Refer to Chapter 7 and reconnect the
gear shift mechanism to the transmission,
then check the overall operation of the
gear shift mechanism, adjusting it if
necessary.
c) Refer to Chapter 6 and reconnect the
clutch cable to the transmission, then
check the operation of the automatic
adjustment mechanism (where
applicable).
d) Ensure that all hoses are correctly routed
and are secured with the correct hose
clips, where applicable. If the hose clips
originally fitted were of the crimp variety,
they cannot be used again; proprietary
worm drive clips must be fitted in their
place, unless otherwise specified.
e) Refill the cooling system as described in
Chapter 1.
f) Refill the engine with appropriate grades
and quantities of oil, as detailed in
Chapter 1.
g) With reference to Chapter 4A or B as
applicable, reconnect the throttle cable
and adjust it as necessary.
h) With reference to Chapter 5B, check and
adjust the engine idle speed and where
applicable, the ignition timing.
37 When the engine is stat-ted for the first
time , check for air, coolant, lubricant and
fuel leaks from manifolds, hoses etc. If the
engine has been overhauled, read the
cautionary notes in Section 13 before
attempting to start it.
1 It is much easier to dismantle and work on
the engine if it is mounted on a portable
engine stand. These stands can often be hired
from a tool hire shop. Before the engine is
mounted on a stand, the flywheel should be
removed, so that the stand bolts can be
tightened into the end of the cylinder block/
crankcase.
2 If a stand is not available, it is possible to
dismantle the engine with it blocked up on a
sturdy workbench, or on the floor. Be very
careful not to tip or drop the engine when
working without a stand.
3 If you intend to obtain a reconditioned
engine, all ancillaries must be removed first, to
be transferred to the replacement engine (just
as they will if you are doing a complete engine
overhaul yourself). These components include
the following:
a) Alternator (including mounting brackets)
and starter motor (Chapter 5A).
b) The ignition system and HT components
including all sensors, distributor, HT leads
and spark plugs (Chapters 1 and 5).
c) The fuel injection system components
(Chapter 4 Parts A and B)
d) All electrical switches, actuators and
sensors, and the engine wiring harness
(Chapter 4 Parts A and B, Chapter 5B).
e) inlet and exhaust manifolds (Chapter 2A).
f) The engine oil level dipstick (Chapter 1)
g) Engine mountings (Chapter 2A and B).
h) Flywheel (Chapter 28)
i) Clutch components (Chapter 6)
Note: When removing the external
components from the engine, pay close
attention to details that may be helpful or
important during refitting. Note the fitted
position of gaskets, seals, spacers, pins,
washers, bolts, and other small components.
4 If you are obtaining a “short” engine (which
consists of the engine cylinder block/
crankcase, crankshaft, pistons and
connecting rods, all fully assembled), then the
cylinder head, sump and baffle plate, oil
pump, timing belt (together with its tensioner
and covers), auxiliary belt (together with its
tensioner), coolant pump, thermostat housing,
coolant outlet elbows, oil filter housing and
where applicable oil cooler will also have to be
removed.
5 If you are planning a complete overhaul, the
engine can be dismantled in the order given
below:
a) Inlet and exhaust manifolds.
b) Timing be/t, sprockets and tensioner.
c) Cylinder head.
d) Flywheel driveplate.
e) Sump.
f) Oil pump.
g) Piston/connecting rod assemblies.
h) Crankshaft.
6 Before beginning the dismantling and
overhaul procedures, make sure that you have
all of the tools necessary. Refer to “Tools and
working facilities” in the Reference Section of
this manual for further information.