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Volkswagen Workshop Service and Repair Manuals

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Securing engine to assembly stand > < Removing and installing engine

Golf Mk4

Notes on removing
Notes on removing
  Note
Before carrying out further work, disconnect battery earth strap. First check whether a coded radio is fitted. Obtain anti-theft coding first if necessary.
–  The engine is removed downwards together with the gearbox.
–  All cable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed.
–  With the ignition switched off, disconnect battery earth strap.
–  Remove engine cover.
–  Drain coolant → Chapter.
–  Remove battery and battery retainer.
   
–  Pull off supply hose -1- (with white marking) and return hose -2- (with blue marking) and catch fuel that escapes in a cloth.
–  Pull hose off activated charcoal filter system solenoid valve 1 -N80--3-.
  WARNING
Fuel system is under pressure! Before opening the system place a cloth around the connection. Then release pressure by carefully loosening the connection.
  Note
Press in securing ring to release fuel lines.
–  Seal lines so that fuel system is not contaminated by dirt.
–  Detach connectors from the following components:
t  Ignition transformer -N152-
t  Hall sender -G40-
t  Injector, cylinder 1 -N30-
t  Injector, cylinder 2 -N31-
t  Injector, cylinder 3 -N32-
t  Injector, cylinder 4 -N33-
t  Coolant temperature sender -G62-
t  Engine speed sender -G28-
t  Knock sensor 1 -G61-
t  Exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-
t  Secondary air pump motor -V101-
t  Oil pressure switch -F1-
t  Air mass meter -G70-
t  Throttle valve module -J338-
t  If necessary, air conditioning system switch off thermal switch -F163-
–  Remove air filter with intake hose and air mass meter -G70-.
–  Remove upper part of intake manifold.
  Note
Seal intake ports in lower part of intake manifold using a clean cloth.
Vehicles with manual gearbox
–  Disconnect selector mechanism from gearbox: → Rep. gr.34.
–  Remove hydraulic clutch slave cylinder: → Rep. gr.30.
  Note
Clutch pedal must not be depressed.
Vehicles with automatic gearbox
–  Remove selector lever cable from gearbox: → Rep. gr.37.
Continuation for all vehicles
–  Remove poly V-belt → Chapter.
–  Remove securing clamps for power-assisted steering pressure line.
–  Unbolt power assisted steering vane pump from bracket and lay to side, hoses remain connected: → Rep. gr.48.
Vehicles with air conditioning system:
–  Remove air conditioner compressor:
–  Observe additional information and installation work → Chapter.
–  Remove inter-connecting, coolant, vacuum and intake hoses on engine.
–  Remove secondary air pump and bracket.
–  Disconnect all electrical wiring from gearbox, alternator and starter and lay to side.
–  Pull off or disconnect all other electrical connections as necessary from engine and lay to side.
  A10-0169
–  Disconnect pendulum support -arrows-.
–  Remove inner right constant velocity joint protective cap from engine.
–  Remove right drive shaft and disconnect left drive shaft at gearbox: → Rep. gr.40.
–  Remove front exhaust pipe → Chapter
–  Insert engine bracket -T10012- in engine and gearbox jack -V.A.G 1383 A-.
  A37-0200
–  Remove front stud and fit engine bracket -T10012- onto cylinder block with securing nut and M10×25/ 8.8 bolt and tighten to approx. 40 Nm.
–  Tighten securing nut exhaust side by hand.
–  Lift engine and gearbox lightly using engine and gearbox jack -V.A.G 1383 A-.
  N10-0056
–  From above, unscrew assembly mounting engine side from engine bracket -arrows-.
  Note
To remove securing bolts use a stepladder -VAS 5085-.
  A10-0125
–  Unbolt gearbox side of assembly mounting from gearbox bracket from above -arrows-.
–  Carefully lower engine with gearbox.
  Note
Engine and gearbox must be guided carefully when lowering to prevent damage to the bodywork, hoses and lines.
  A10-0126

Securing engine to assembly stand > < Removing and installing engine