REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
NOTE: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle.
NOTE: For reassembly reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place mating
marks on other major assemblies before removal.
WARNING: Radio/cassette or radio/CD player is equipped with an
anti-theft protection circuit. Whenever battery is
disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE, and will be
inoperative until proper code number is entered. Obtain
security code before disconnecting battery.
FUEL PRESSURE RELEASE
Remove fuel pump relay (lower right relay located in
fuse/relay panel). start engine and let idle until it stalls. Crank
engine for an additional 5 seconds. Reinstall fuel pump relay.
ENGINE
NOTE: Engine is removed with transaxle attached.
Removal
1) Obtain radio code. Turn ignition off and wait 20 seconds.
Disconnect negative battery cable. Remove air cleaner assembly.
Install 8-mm bolt in belt tensioner hole and remove accessory drive
belt. See Fig. 2.
2) On manual transmission models, disconnect clutch slave
cylinder. On all models, remove power steering pump and attach to
body. DO NOT disconnect power steering hoses. Remove radiator, front
lock support and front bumper. Drain cooling system. Disconnect
cooling fan and thermoswitch.
Fig. 2: Releasing Accessory Drive Belt Tensioner
Courtesy of Volkswagen United States, Inc.
3) Label and disconnect all electrical wiring, control
cables, coolant hoses and vacuum hoses from engine/transaxle assembly.
Disconnect throttle, cruise and kickdown linkage (if equipped). Remove
air duct from intake manifold.
4) Disconnect drive axles from transaxle. See FWD AXLE SHAFTS
