Removal and installation of the power unit VR6
The power unit is removed from the engine compartment down. After that, you can disconnect the gearbox from the engine. Before proceeding with the removal of the Volkswagen Transporter T4 , you must read the general instructions:
To remove the engine from the car, a car lift is required.
To remove the engine, it is necessary to dismantle the front panel of the car, also remove the battery and rubber-metal engine mounts.
To prevent damage to the electronic microprocessor module of the engine management system, the battery can only be disconnected when the ignition is off.
In this case, it should be remembered that, after turning off the ignition, it is necessary to wait at least another 20 seconds and, only after that, you can remove the terminals from the battery. The hot filament of the air flow meter should glow brightly until the electrical circuit opens. Most of the wires are secured with plastic straps or clamps.
When disconnecting the harnesses, their mounting position should be marked, and when installing the engine, the harnesses should be fixed in their original place. Some clamps must be cut to remove. In such cases, use new clamps. Powertrain Removal and Installation - Manual Transmission Vehicles
♦ Disconnect the battery terminals, remove the battery.
♦ Set the heater control to the “warm” position.
♦ Remove the screw plug from the coolant expansion tank.
When removing the power unit, it should be cold. ♦ Remove the air filter.
Close the openings so that dust cannot enter the motor. ♦ Drain the cooling system.
The top cooling pipe has a drain plug that can be removed. Or, just remove the clamp and remove the lower hose from the radiator. The heater valve must be open so that all coolant from the heater can flow out. ♦ Remove the upper coolant hose clamp, disconnect the hose from the cylinder head.
Disconnect the hose from the radiator. ♦ Disconnect the wire from the radiator fan thermal switch.
♦ Disconnect the wire connector from the back cover of the generator.
♦ Remove the vacuum hoses from the top of the intake manifold.
♦ Remove all other coolant hoses (from cylinder head, water pump and expansion tank).
♦ With the fasteners disengaged, remove the radiator assembly from the engine compartment.
♦ Disconnect the wire from the engine oil pressure sensor (1.8 bar).
This is the connector with the yellow wire. Also disconnect the 0.3 bar sensor wire. This is a connector with a bluish-black wire. ♦ Disconnect the engine temperature sensor connector.
♦ Remove the central high voltage wire of the ignition distributor.
♦ Disconnect the ignition distributor connector.
Disconnect the wires from the gearbox. ♦ Disconnect the air temperature sensor.
♦ To remove the Transporter T4 power unit, disconnect the wires between the body and the engine, having previously marked these wires for ease of reassembly.
Keep the wires out of the way so they don't get in the way. Disconnect the ground bar from the valve cover of the block head. ♦ Disconnect the wires from the starter.
Disconnect the wires from the gearbox. ♦ Detach the clutch master cylinder from the transmission, leave it hanging from the hoses and wire it to the chassis.
Disconnect the ground bar from the gearbox. ♦ Loosen and remove the tachometer cable from the gearbox.
Close the opening in the gearbox so that dust cannot get in. ♦ Disconnect the throttle link from the bracket and sector.
♦ Do not remove the clamp from the throttle linkage.
♦ Disconnect the air duct from the air filter housing.
♦ Disconnect the vacuum hose from the air filter housing.
♦ Disconnect the hose from the brake booster.
♦ Unscrew the power steering pump from the bracket and secure it with a wire in a hanging position on the engine support bracket without disconnecting the pipes/hoses.
♦ Remove the engine from its stands using a steel cable to secure the engine to the winch.
The V workshops use a special traverse for this purpose. ♦ Fully unscrew and remove the front rubber-metal support.
♦ Unscrew the two remaining engine mounts and remove them.
Check if the motor is hanging securely on the cable. ♦ Disconnect the shift rods from the gearbox.
♦ Disconnect the wires from the reversing light switch.
♦ Detach the drive shafts from the box and tie them horizontally to the body with a wire.
To unscrew the bolts, it is convenient to use an 8 mm socket wrench (similar to the wrench for unscrewing bolts with an internal hexagon type Tox). ♦ Disconnect the front exhaust pipe from the exhaust manifold and from the transmission.
Raise the engine to relieve the mounts. Check if all connections are disconnected between the engine, gearbox and body. ♦ Disconnect the engine from the gearbox and lower it down.
Installation of the power unit is carried out in the reverse order, while observing the following recommendations:
♦ Install the engine and gearbox in the engine compartment, first tighten the engine cross member bolts, then the gearbox cross member bolts.
♦ Loosen the engine mount bracket, align the engine with no interference, then tighten the engine mount bolts.
♦ Reattach the drive shafts, tighten the respective bolts to the recommended tightening torque of 45 Nm.
♦ After installing the power package, connect the exhaust system.
Align the muffler and exhaust pipe and secure them with the rubber ring. If the rubber ring is strongly stretched under the weight of the parts, then the fastening hook of the exhaust pipe can be slightly bent. If the rubber ring is under excessive tension, it will quickly break. ♦ Pour liquid into the cooling system after checking whether the heater cock is open. Fill the expansion tank to the “MAX” mark, tighten the cap. Run the engine for a short period of time to purge air from the cooling system. In conclusion, check the coolant level, if necessary, bring it to normal.
See VR6 Engine T4 Oil Pressure .