VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing engine

Removing engine

Special tools and workshop equipment required
Removal lever -80 - 200-
Extension -2024 A /1- of lifting tackle -2024 A-
Engine and gearbox jack -V.A.G 1383 A- or -VAS 6931-
Engine bracket -T10497-
Drip tray for workshop hoist -VAS 6208-
Hose clip pliers -VAS 6362-

 
 
   
Locking pin -T10060 A-
Commercially available stepladder
Eye protection
Protective gloves
Procedure
  Note
The engine is removed downwards together with the gearbox.
Reinstall all cable ties in the same locations when installing.
The cooling system is under pressure when the engine is hot. Hot steam/hot coolant can escape - risk of scalding. Risk of scalding to skin and body parts.Wear protective gloves.Wear eye protection.Release pressure by covering cap of coolant expansion tank with a cloth and opening it carefully.
 

Removing engine

–  Open cap -arrow- on coolant expansion tank.
–  Remove left and right front wheel → Running gear, axles, steering; Rep. gr.44.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Remove left and right front wheel housing liner → General body repairs, exterior; Rep. gr.66.
–  Disconnect connector -2- from radiator outlet coolant temperature sender -G83--3-.
–  Set drip tray for workshop hoist -VAS 6208- underneath.
 

Removing engine

–  Lift retaining clip -1-, disconnect coolant hose from radiator (bottom left) and drain off coolant.
  Note
Do not reuse coolant which has been drained off.
 

Removing engine

–  Lift retaining clip -arrow-, disconnect coolant hose from water radiator (bottom right) for charge air cooling circuit and drain off coolant.
–  If poly V-belt is to be reinstalled, mark direction of rotation on belt using chalk or felt tip pen before removing.
Vehicles with air conditioner compressor:
 

Removing engine

–  To slacken poly V-belt, swivel tensioning device in anti-clockwise direction -arrow-, and detach poly V-belt from pulley for air conditioner compressor.
–  Lock tensioner with locking pin -T10060 A-.
–  Remove poly V-belt.
Risk of freezing injury caused by refrigerant.Do not open refrigerant circuit of air conditioning system.
 

Removing engine

–  Disconnect connector -1- on air conditioner compressor regulating valve -N280-.
–  Remove bolts -arrows- for air conditioner compressor.
–  Detach air conditioner compressor from bracket (refrigerant hoses remain connected) and tie up to right side. Do NOT stretch, kink or bend refrigerant lines and hoses while doing so.
Continuation for all vehicles:
–  Release hose clip -1- and detach air hose.
 

Removing engine

–  Unscrew bolt -2- on left and right.
–  Unclip air duct at lock carrier and detach.
 

Removing engine

–  Lift retaining clip -arrow- and disconnect coolant hose (top left) from radiator.
 

Removing engine

–  Lift retaining clip -arrow- and disconnect coolant hose (top right) from water radiator for charge air cooling circuit.
 

Removing engine

–  Unplug electrical connector -1- for radiator fan (push retainer to the rear -arrow A- and press down release catch).
–  Press locking tabs on left and right sides of radiator cowl -arrow B- and at the same time lift radiator cowl off radiator.
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove battery and battery tray → Electrical system; Rep. gr.27.
 

Removing engine

–  Release catch -arrow- and disconnect vacuum hose -1-.
–  Move clear vacuum hose at air pipe -2-.
Vehicles with no auxiliary heater
 

Removing engine

–  Lift retaining clips -arrows- and disconnect coolant hoses from heat exchanger for heater.
Vehicles with auxiliary heater
 

Removing engine

–  Release retaining clip and hose clip and pull off both coolant hoses -arrows-.
Vehicles with engine preheater heater element -Z97-
–  Unclip locking mechanism -arrow-.
 

Removing engine

–  Pull off wiring -1- on engine preheater heater element -Z97--2-.
–  Unclip all cable ties from wiring harness -1- on engine and secure wiring harness on one side of the vehicle.
–  Pull off lower coolant hose on engine preheating element -Z97- and remove coolant pipe.
 

Removing engine

–  Unscrew nuts -arrows- and remove engine preheating element -Z97- with bracket.
Continuation for all vehicles
 

Removing engine

–  Unscrew bolt -2- and remove screw-type clip.
–  Remove bolt -1- and nuts -arrows- and tie up catalytic converter.
 

Removing engine

–  Undo bolts -arrow- and remove bracket.
  Note
Place a cloth underneath to absorb escaping coolant.
 

Removing engine

Release hose clip -1- and pull off coolant hose.
The fuel system is pressurised.Risk of injury due to fuel which may spurt out.Wear eye protection.Wear protective gloves.Release pressure: place clean cloth around connection and carefully open connection.
–  Observe the rules for cleanliness when working on the fuel supply system → Chapter.
–  First press hose connector -1- downwards, and then press release tabs -arrows-.
 

Removing engine

–  Keep release buttons pressed and pull off hose coupling.
–  Press release tab on hose -2- connected to activated charcoal filter.
–  Disconnect hose and move it clear.
–  Detach air hose -2-.
–  Remove air filter housing → Chapter.
  Note
 

Removing engine

For the work steps below use removal lever -80 - 200- to unclip the binding clips.
 

Removing engine

–  Unplug upper electrical connector -1- at engine control unit -J623- → Chapter.
–  Take electrical connectors -2- and -3- out of retainer and detach.
–  Move electrical lines free.
 

Removing engine

–  Disconnect electrical connector -2-.
–  Push back cover for battery positive terminal -1- and unbolt battery positive cable from starter solenoid switch.
–  Unbolt earth cable from body.
 

Removing engine

–  Release catches -arrows- and detach cover -1- for electronics box in engine compartment.
 

Removing engine

–  Release catch using a screwdriver -arrow- and detach cover -1- for electronics box in engine compartment upwards.
 

Removing engine

–  Remove nut -arrow-, detach electrical wiring and move clear.
 

Removing engine

–  Disconnect electrical connectors -1- and -2-.
Manual gearbox
–  Remove selector mechanism from gearbox → Rep. gr.34.
–  Remove clutch slave cylinder → Rep. gr.30.
Dual clutch gearbox
–  Remove selector lever cable, pull connector of mechatronic off and remove all retainers from gearbox: → Rep. gr.34
Continuation for all vehicles
 

Removing engine

–  Unscrew bolts -arrows- on engine mounting approx. 2 turns.
 

Removing engine

–  Unscrew bolts -arrows- on gearbox mounting approx. 2 turns.
 

Removing engine

–  Disconnect electrical connector -1- on oil level and oil temperature sender -G266-.
–  Detach wire from retainer -2-.
 

Removing engine

–  Unscrew nuts for coupling rod -arrow- on left and right from anti-roll bar.
 

Removing engine

–  Unscrew bolts -1, 2 and 3-, and remove pendulum support.
 

Removing engine

–  Unscrew bolts -arrows- and remove heat shield for right drive shaft.
 

Removing engine

–  Unscrew nuts -arrows- for swivel joint on left and right.
 

Removing engine

–  If fitted, remove nut -arrow- from front left vehicle level sender -G78-.
–  Detach swivel joint from transverse link on left and right.
–  Unbolt drive shaft from gearbox on left and right, and tie it up → Running gear, axles, steering; Rep. gr.40.
  Note
Take care not to damage the surface protection of the drive shaft.
 

Removing engine

–  Swivel left suspension strut outwards and support it with extension -2024 A /1- as shown in illustration.
–  Secure locking pin and swivel joint with locating pin -arrow- and nut -1-.
 

Removing engine

–  Secure swivel joint -2- (right-side) to transverse link -1- with nut -arrow-, as shown in illustration.
–  Apply clamping piece T10497/2 at housing rib on cylinder block, as shown in illustration.
Vehicles with four-wheel drive
–  Unbolt flexible coupling of propshaft from bevel box → Final drive, differential; Rep. gr.39.
Continuation for all vehicles
 

Removing engine

–  Position engine support T10497 with pin T10497/1 on cylinder block.
–  Screw in bolt -1- through hole “B” in engine support T10497 and tighten it to 20 Nm.
 

Removing engine

–  Fit adapter -T10497/3- to engine support -T10497- and tighten bolt -1- to 20 Nm.
–  Insert engine and gearbox jack -V.A.G 1383 A- in engine support T10497 and raise engine/gearbox assembly slightly.
  Note
To unscrew bolts for assembly mounting use commercially available stepladder.
 

Removing engine

–  Remove bolts -arrows- for engine mounting.
 

Removing engine

–  Remove bolts -arrows- securing gearbox mounting.
  Note
Danger of damage to vacuum lines or electrical wiring and to engine compartment.
Check that all vacuum lines and electrical wiring between engine, gearbox, subframe and body have been detached.
When lowering, carefully guide engine/gearbox assembly with assembly carrier out of engine compartment.
–  First lower engine/gearbox assembly slightly.
–  Then push gearbox end of engine/gearbox assembly forwards and only then lower further.
 

Removing engine

Removing and installing engine
...

Separating engine and gearbox
Special tools and workshop equipment required     Shackle -10 - 222 A /12-   ...

Other materials:

Aquaplus blending system
Designation: Blending additive for Aquaplus -LVM 030 000 A2- Issued 06/2011 Product description The blending additive for Aquaplus is especially suitable for blending in Aqua ...

Removing and installing automatic anti-dazzle interior mirror, with rain and light sensor -G397- and front camera for driver assist systems -R242-
Removing –  Unclip front cover -1- from front interior light -W1- and pull it downwards by approx. 10 mm -arrows A-. –  Release locking lugs -3- using as small screwdriver. ...

Removing and installing wheel bearing unit, multi-link suspension, front-wheel drive
Special tools and workshop equipment required Fitting sleeve -3241/4- Hub grease cap puller -VW 637/2- Torque wrench -V.A.G 1332- Tool insert -T10162 A- Torque wrench -V.A.G 1410-   ...

© 2016-2019 Copyright www.vwgolf.org