volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Securing engine to assembly stand > < Removing and installing engine

Golf Mk4

Removing engine
Removing engine
  Note
t  Before carrying out further work, disconnect battery earth strap. Check whether a coded radio is fitted. Obtain anti-theft coding first 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.
–  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
–  Remove engine cover.
–  Remove battery and battery carrier.
–  Remove air cleaner.
–  Vehicles with turbocharger: release clamps of connecting pipe between charge air cooler and intake manifold on intake manifold.
  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!
–  Disconnect fuel supply and return lines at fuel filter.
–  Remove hydraulic clutch slave cylinder: → Rep. Gr.30
–  Disconnect selector mechanism from gearbox: → Rep. Gr.34
–  Vehicles with an automatic gearbox: remove gate selector cable from gearbox: → Rep. Gr.37
–  Remove centre, left and right insulation trays → Rep. Gr.50
–  Drain coolant.
–  Pull connectors off thermal switch and radiator fan.
–  Pull radiator coolant hoses off engine using hose clip pliers -V.A.G 1921-.
   
–  Disconnect pendulum support -arrows-.
–  Pull vacuum and breather hoses off engine.
–  Disconnect all electric wires from gearbox, alternator and starter and lay to side.
–  On vehicles with four-wheel drive, remove front propshaft tube: → Rep. Gr.39
–  Remove front exhaust exhaust pipe, removing and installing parts of exhaust system.
–  Remove poly V-belt.
–  Unscrew power steering vane pump on bracket and place to one side, hoses remain connected: → Rep. Gr.48
–  Pull off or disconnect all other electrical connections as necessary from engine and lay clear.
–  Remove right-hand drive shaft and unbolt left-hand drive shaft at gearbox: → Rep. Gr.40
–  Remove securing clamps for power steering pressure line.
–  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.
  A37-0200
–  Fit engine bracket -T10012- onto cylinder block with securing nut and M10 X 25/ 8.8 bolt and tighten to approx. 40 Nm.
–  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.
  N10-0056
–  Unbolt engine side of assembly mounting from engine bracket from above -arrows-.
  Note
To remove securing bolts, use stepladder -VAS 5085-.
  A10-0125
–  Unbolt gearbox side of assembly mounting from gearbox bracket -arrows- from above.
–  Carefully lower engine with gearbox.
  Note
Engine with gearbox must be guided carefully when lowered to prevent damage to bodywork.
  A10-0126

Securing engine to assembly stand > < Removing and installing engine