Volkswagen Workshop Service and Repair Manuals

Removing engine (Golf, Golf Plus)

Special tools and workshop equipment required

t	Lifting tackle -2024 A-

t	Engine bracket -T10012-

t	Support clamp -VW 313-

t	Engine and gearbox support -VW 540-

t	Workshop hoist -V.A.G 1202 A-

t	Drip tray -V.A.G 1306-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Spring-type clip pliers -VAS 5024-

t	Stepladder -VAS 5085-

t	Guide rods -T10093-

t	Cable ties

Note t  Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted and obtain anti-theft coding if necessary. t  The engine is removed downwards together with the gearbox. t  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.   WARNING When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions: t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions. t  Ensure that there is sufficient clearance to all moving or hot components. Procedure –  With ignition switched off, disconnect earth strap from battery.

One-piece engine cover For one-piece engine cover, pull engine cover abruptly upwards at front and right -arrows A-, then pull forwards out of rear fastening -arrow B-.

Two-piece engine cover For two-piece engine cover, first pull outer engine cover abruptly upwards at -arrows-, then pull inner engine cover abruptly upwards at -arrows-. –  Remove plenum chamber bulkhead. → General body repairs, exterior; Rep. gr.50. –  Remove air filter housing with air mass meter and connecting pipe.

–  Remove bolt -arrow A- and pull air filter housing upwards out of mounting. –  Remove battery and battery tray. –  Disconnect fuel supply and return lines as well as coolant line on cylinder head.   WARNING t  The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)! t  The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure! t  Wear eye and hand protection when performing any type of repair work on the fuel system! –  Remove noise insulation → General body repairs, exterior; Rep. gr.50. –  Bring lock carrier into service position → General body repairs, exterior; Rep. gr.50. –  Drain coolant → Chapter. Vehicles with air conditioner   Note To prevent damage to condenser or to refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent. To facilitate removing and installing engine without opening refrigerant circuit: –  Remove poly V-belt → Chapter. –  Remove air conditioner compressor → Heating, air conditioning; Rep. gr.87. –  Secure air conditioner compressor to lock carrier so that refrigerant lines/hoses are free of stress. –  Remove alternator → Electrical system; Rep. gr.27. Continuation for all vehicles –  Remove connecting pipes between charge air cooler and engine. –  Unbolt left and right-hand drive shafts from gearbox → Running gear, axles, steering; Rep. gr.40. –  Remove front exhaust pipe → Chapter. –  Release connector from engine control unit, disconnect connector.

–  Open all cable guide fasteners -arrows-. –  Remove wiring harness from cable guide on longitudinal member and lay to side on engine. –  Pull off or disconnect all other electrical connections from engine and gearbox as necessary and lay to side. –  Separate all connecting, coolant, vacuum and intake hoses from engine. Vehicles with manual gearbox –  Remove slave cylinder for hydraulic clutch. → 6-speed manual gearbox 02S; Rep. gr.30. –  Unbolt selector mechanism from gearbox → 6-speed manual gearbox 02S; Rep. gr.34. Vehicles with four-wheel drive: –  Remove selector mechanism from gearbox → 6-speed manual gearbox 02Q, four-wheel drive; Rep. gr.34. –  Separate pressure line for hydraulic clutch control. –  Remove front propshaft → Final drive 02D, 0AV; Rep. gr.39. Continuation for all vehicles:

–  Unbolt pendulum support -arrows-. Vehicles with particulate filter –  Remove subframe → Running gear, axles, steering; Rep. gr.40. –  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40. –  Remove steering box → Running gear, axles, steering; Rep. gr.48. Continuation for all vehicles:

–  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.   Note Support pins must be secured to engine bracket -T10012- as shown. –  Fit engine bracket -T10012- to cylinder block with M10 x 25/ 8.8 bolt and tighten to approx. 40 Nm. –  Raise engine and gearbox slightly using engine and gearbox jack -V.A.G 1383 A-.

–  Unbolt assembly mounting on engine side from engine bracket -arrows-.   Note To remove securing bolts, use stepladder -VAS 5085-.

–  Unbolt assembly mounting on gearbox side from gearbox bracket -arrows-. –  Carefully lower engine with gearbox.   Note Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork.