Removal and Installation of the 1600i Engine

IMPORTANT SAFETY FIRST !" Before you even attempt to remove a 1600i engine, please make sure that the vehicle is properly supported (dont forget a typical beetle can weigh about 8 0!g ""#$ Neve# $o#% &nde#neath a vehi'le &sing it(s o$n )a'% as the onl* means of s&++o#t, If the )a'% fails then the#e is a #is% of se#io&s in)&#* o# death Al$a*s &se high -&alit* tools, The investment *o& ma%e in them no$ $ill se#io&sl* +a* off late# on,

P#e+a#ing the 'a# +#io# to #aising the vehi'le!" %ngage the handbrake$ &isconnect the battery earth connection to prevent any damage to the vehicle and for your own safety$ 'lamp the petrol hose from the fuel tank to prevent any fuel spillage by using a plastic hose clamp$ Neve# use pliers, ad(ustable spanners nor )olegrips to clamp fuel hoses$ *his dangerous practice will chaff the fuel hose cause fuel leaks later on$ &o not release the pressure from the fuel in(ection system by undoing any fuel hoses (ust yet$ *his will be e+plained later on$ ,t may also be a good idea to drain the engine oil whilst the vehicle is on the ground$ Rasing and s&++o#ting the veh'ile!" *o raise and support the vehicle properly (if you dont have a hydraulic vehicle lift#, do the following-. 'hock both front wheels using bricks or wedges at .oth ends of ea'h $heel, )ake sure that the car cannot move$ /aise the rear of the vehicle using a hydraulic trolley (ack (at the center of the chassis# with a strong wooden beam (across the chassis# in front of the gearbo+$ *he wooden beam will also help to lift the car evenly and safely$ ,t would be ideal to raise the rear of the vehicle as high as possible (ideally at least 80cm or nearly 0 feet off the ground#$

1upport the vehicle with an a+le stand and a block of wood on each side of the vehicle$ 2lace the a+le stands at each rear (acking point$ )ake sure that the vehicle is properly supported and cannot move at all$ 3ow slo$l* lower the hydraulic trolley (ack and make sure that the vehicle does not list dangerously or slip off the a+le stands$ ,f it does immediately raise the hydraulic trolley (ack and reposition the a+le stands to make sure that the vehicle is supported safely$

P#e+a#ing the 'a# +#io# to engine #emoval!" 3ow release the pressure within the fuel in(ection system$ *his can be done by pressing the thumbscrew on the left hand fuel in(ection distributor inwards as shown in the photo below-.

3ote- *ry not to get covered with petrol as you release the pressure from the fuel in(ection distributor$

3ow remove the air filter unit$ *he overall layout (which will be referred to# is shown below-.

*he air filter can be removed by doing the following-. &isconnect the oil breather hose (1# &isconnect the idle speed stabili4er pipe (5#$ 6ndo the clamp at the bottom of the air filter unit (0#$

*he air filter unit can now be lifted off the throttle body$ 3ow undo the accelerator cable bolt and remove the accelerator cable from the throttle body as shown below-.

Note! 7lder 1600i beetles have the larger white activated charchol filter valve$

3ow undo the hose for the magnetic valve (1# for the activated charchol filter and move the hose towards the right hand side of the vehicle (5# as shown below-.

3e+t unscrew and separate the big black round 58 pin engine bay connector as shown below-.

3ow disconnect the vacuum hoses from the inlet manifold (1# and move them towards the left hand side of the vehicle (5# as shown in the photo below-.

Note! *he upper vacuum hose goes to the fuel pressure regulator at the rear of the engine bay$ 7n older 1600i beetles this vacuum hose is white$

*he heat e+changer lever cables should now be disconnected$ *his can be done by going underneath the car and undoing the heat e+changer lever bolts on the heat e+changer cable clamps as shown in the photo below (arrowed#-.

Note! Be careful not to lose the heat e+changer cable clamps$

3ow disconnect the reverse lights connector by the gearbo+ as indicated by the red circle in the photo below-.

3ow disconnect the alternator to starter motor cable (0# as shown in the photo below-.

/e* to sta#te# moto#0solonoid +hoto!" 1e#man 2es'#i+tion 0 Item N&m.e# )agnet.schalter 8nlasser 1 5 0 T#anslation 0 2es'#i+tion 1olonoid 1tarter )otor Battery 9 (terminal B9# ,gnition 1witch 9 (terminal 1 # 8lternator &9 (terminal &9#

*he fuel supply and return hoses should now be disconnected$ *he photo below shows the petrol filter (located underneath the rear left hand seat#-.

1e#man 2es'#i+tion :um ;ang4eitfilter )otor ;ang4eitfilter <om &ruckregler

English T#anslation *o the fuel filter for the engine (supply hose# ;ong life fuel filter =rom the pressure regulator (return hose#

Note! Be careful when you disconnect these hoses since appro+imately 1 litre of petrol will come out from the fuel filter$ >ave a glass container handy to prevent petrol from going everywhere "" &uring engine re.installation, make sure that everything is clean before you re.attach the fuel hoses$ 8lso make sure that you do up the hose clamps up tight to prevent fuel from being sprayed everywhere due to high pressure$ ,t may also be a good idea to change the fuel filter (or every 60,000 km#$ 3ow widthdraw the accelerator cable away from the fan housing as shown in the photo below$ *his will prevent the accelerator cable from being damaged during engine removal$

3e+t remove the rear engine tinware$ *his will make the engine easier to remove from the car$ 3ow make sure that the engine is properly supported either by the trolley (ack on its oil sump or by an engine crane (from above#$ =ailing to do this could result in serious in(ury or death "" ?et a second person to help you to remove the engine safely from the car$ =inally undo the four nuts and bolts which hold the engine onto the gearbo+ as shown in the photos below-.

;ower left nut (in front of the a+le shaft boot#$

;ower right nut (in front of the a+le shaft boot#$

6pper left bolt (from the gearbo+ end#$ Note! Be careful when you undo these bolts$ )ake sure that the engine is properly supported$ =ailing to do this can result in death "" *hree of the nuts@bolts are standard 1Amm bolts, where as the upper right bolt is a 10mm bolt which mounts the starter motor onto the gearbo+$

3ow carefully move the engine backwards away from the gearbo+ and make sure that the flywheel is clear of the gearbo+s input shaft$ )ake sure that the engine does not tilt off.a+is in any way whilst you do this$ 8lso be particularly careful with the plastic fuel distributors when you are removing the engine from the car$ *hese can get very easily damaged or broken$ *he engine can now be lowered (taking care not to damage the bodywork nor fuel distributors# and removed from underneath the car$ Engine Installation!" *his is pretty much the reverse of removal$ Before you put the engine back into the car, check the state of the clutch and replace it if its soiled or suspect$ 3ow make sure that the clutch is centered within the clutch plate$ *his can be simply be done by using a BC short bar from a socket set$ 3ow check the clutch thrower bearing (in the gearbo+s bell housing#$ /eplace this if suspect$ 'arefully lift (or raise# the engine back into position$ )ake sure that the engine is absolutely sDuare with the gearbo+ when you move the engine towards the gearbo+$ *his will prevent any damage to the gearbo+s input shaft$ Ehen the engine is absolutely sDuare with the gearbo+ (and the two are completely in place#, re.install the lower nuts and bolts first$ 7nly do these up finger tight for now$ 3ow re.install the upper nuts and bolts and tighten all four of them up fully$ Neve# rely on the nuts and bolts to force the engine towards the gearbo+ """ Note! ,f the engine will not fit the gearbo+ properly, then turn gearbo+s input shaft$ *he engine should then fit completely sDuare onto the gearbo+$ /e.install all of the other bits (including the rear engine tinware# mentioned during the engine removal process$

A''ele#ato# 3a.le Ad)&stment!" Ehen you re.install the accelerator cable, make sure that the tension of it is ad(usted correctly$ )ake sure that the gap between the accelerator cam and its end.stop is appro+imately 5 mm to 0mm when the accelerator pedal is pushed down fully$ *his is indicated by the red arrows in the photo below-.