4 Cylinder Engine W/Automatic Transmission

1. Disconnect battery ground cable.
2. On vehicles with air conditioning, proceed as follows:
a. Remove clips and screw securing grille, then the grille.
b. Remove condenser to radiator attaching bolts.
c. Remove air duct from throttle valve housing and the hose from air duct to auxiliary air regulator.
d. Remove fuel distributor, air flow sensor, fuel injectors and air cleaner as an assembly, leaving fuel lines connected and capping injectors and cold start valve.
e. Remove engine stop attaching bolts and the stop.
f. Loosen nuts attaching outer half of crankshaft pulley and remove drive belt.
g. Discharge refrigerant, then remove air conditioner hoses and plug openings.
h. Disconnect compressor clutch wire.
i. Remove crankcase vent hose connection at valve cover and position air conditioner hoses out of way.
j. Remove two upper and three lower compressor mounting bolts and the compressor.
3. Open heater control valve, remove cap from expansion tank, and drain coolant by disconnecting lower radiator hose.
4. Remove upper and lower radiator hoses.
5. Disconnect electrical connectors for radiator fan and thermo switch.
6. Remove radiator rubber mounts, then the radiator, fan and fan shroud as an assembly.
7. Disconnect engine electrical connectors as necessary.
8. Remove control pressure regulator, leaving fuel lines connected.
9. Disconnect alternator wiring and position out of way.
10. Disconnect electrical connectors of oil pressure switch and coolant temperature sender.
11. Disconnect wiring at ignition coil terminals 1 and 4.
12. Remove heater hose adjacent to ignition coil.
13. Disconnect vacuum hose at retard connection on ignition distributor.
14. Disconnect hoses at intake manifold.
15. Remove throttle cable and the rubber air duct.
16. On vehicles less air conditioning, remove fuel injectors and cold start valve, leaving fuel lines connected and capping injectors and cold start valve.
17. Disconnect hose between auxiliary air regulator and air duct.
18. On all vehicles, remove upper engine to transmission mounting bolts.
19. Remove left and right engine mount attaching nuts.
20. Remove exhaust pipe attaching nuts from manifold, then the pipe.
21. Loosen and remove power steering drive belt, then remove power steering pump, leaving hoses attached, and position out of way.
22. Remove bolts attaching inspection plate and the plate.
23. Disconnect and tag starter electrical connections.
24. Remove starter mounting bolts and the starter.
25. Working through starter mounting hole, remove torque converter attaching bolts.
26. Remove bolts from exhaust pipe hanger and catalytic converter/muffler flange.
27. Remove engine stop attaching bolts and the stop, if not previously removed.
28. Install transmission support bar VW758/1 or equivalent with slight preload.
29. Attach suitable lifting device to engine and lift engine enough to take weight off engine mounts.
30. Adjust support bar to contact transmission housing.
31. Remove engine to transmission attaching bolts and pry engine and transmission apart.
32. Lift engine out of vehicle.
33. Reverse procedure to install, noting the following:
a. Tighten engine mount and subframe bolts with engine running at idle.
b. Torque bolts and/or nuts as follows: cold start valve, 7 ft.lbs., control pressure regulator, 14 ft.lbs., engine cover plate, 7 ft.lbs., engine to transmission attaching bolts, 40 ft.lbs., engine mount attaching bolts, 25 ft.lbs., engine stop to block attaching bolts, 18 ft.lbs., exhaust pipe hanger, 18 ft.lbs., exhaust pipe to manifold attaching bolts, 22 ft.lbs., power steering pump, 14 ft.lbs., radiator mounting bolts, 7 ft.lbs., starter mounting bolts, 14 ft.lbs., and torque converter mounting bolts, 22 ft.lbs.
c. On vehicles equipped with air conditioning, adjust compressor drive belt by varying number of shims behind outer half of pulley.
d. Torque air conditioner compressor bracket to engine upper bolts to 22 ft.lbs. and lower bolts to 18 ft.lbs.