Volkswagen Golf Service & Repair Manual: Removing engine
| Special tools and workshop equipment required |
| Extension -2024 A /1- of lifting tackle -2024 A- |
| Engine and gearbox jack -V.A.G 1383 A- or -VAS 6931- |
| Drip tray for workshop hoist -VAS 6208- |
| Hose clip pliers -VAS 6362- |
| Commercially available stepladder |
 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. |
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Open cap -arrow- on coolant
expansion tank. |
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Remove left and right front wheel
→ Running gear, axles, steering; Rep. gr.44. |
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Remove noise insulation
→ General body repairs, exterior; Rep. gr.66. |
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Remove left and right front wheel housing liner
→ General body repairs, exterior; Rep. gr.66. |
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Disconnect connector -2- from
radiator outlet coolant temperature sender -G83--3-. |
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Set drip tray for workshop hoist -VAS 6208- underneath. |
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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. |
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Lift retaining clip -arrow-,
disconnect coolant hose from water radiator (bottom right) for
charge air cooling circuit and drain off coolant. |
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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: |
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To slacken poly V-belt, swivel tensioning device in
anti-clockwise direction -arrow-,
and detach poly V-belt from pulley for air conditioner
compressor. |
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Lock tensioner with locking pin -T10060 A-. |
Risk of freezing injury caused by refrigerant.Do not open refrigerant
circuit of air conditioning system. |
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Disconnect connector -1- on air
conditioner compressor regulating valve -N280-. |
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Remove bolts -arrows- for air
conditioner compressor. |
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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: |
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Release hose clip -1- and
detach air hose. |
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Unscrew bolt -2- on left and
right. |
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Unclip air duct at lock carrier and detach. |
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Lift retaining clip -arrow- and
disconnect coolant hose (top left) from radiator. |
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Lift retaining clip -arrow- and
disconnect coolant hose (top right) from water radiator for
charge air cooling circuit. |
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Unplug electrical connector -1-
for radiator fan (push retainer to the rear
-arrow A- and press down release
catch). |
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Press locking tabs on left and right sides of radiator cowl
-arrow B- and at the same time lift
radiator cowl off radiator. |
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Disconnect battery
→ Electrical system; Rep. gr.27. |
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Remove battery and battery tray
→ Electrical system; Rep. gr.27. |
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Release catch -arrow- and
disconnect vacuum hose -1-. |
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Move clear vacuum hose at air pipe -2-. |
| Vehicles with no auxiliary heater |
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Lift retaining clips -arrows-
and disconnect coolant hoses from heat exchanger for heater. |
| Vehicles with auxiliary heater |
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Release retaining clip and hose clip and pull off both
coolant hoses -arrows-. |
| Vehicles with engine preheater heater element -Z97- |
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Unclip locking mechanism -arrow-. |
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Pull off wiring -1- on engine
preheater heater element -Z97--2-. |
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Unclip all cable ties from wiring harness
-1- on engine and secure wiring
harness on one side of the vehicle. |
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Pull off lower coolant hose on engine preheating element
-Z97- and remove coolant pipe. |
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Unscrew nuts -arrows- and
remove engine preheating element -Z97- with bracket. |
| Continuation for all vehicles |
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Unscrew bolt -2- and remove
screw-type clip. |
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Remove bolt -1- and nuts
-arrows- and tie up catalytic
converter. |
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Undo bolts -arrow- and remove
bracket. |
Note
| Place a cloth underneath to absorb escaping coolant. |
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| 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.
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Observe the rules for cleanliness when working on the fuel
supply system
→ Chapter. |
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First press hose connector -1-
downwards, and then press release tabs
-arrows-. |
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Keep release buttons pressed and pull off hose coupling. |
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Press release tab on hose -2-
connected to activated charcoal filter. |
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Disconnect hose and move it clear. |
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Remove air filter housing
→ Chapter. |
Note
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| For the work steps below use removal lever -80 - 200- to
unclip the binding clips. |
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Unplug upper electrical connector -1-
at engine control unit -J623-
→ Chapter. |
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Take electrical connectors -2-
and -3- out of retainer and detach. |
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Move electrical lines free. |
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Disconnect electrical connector -2-. |
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Push back cover for battery positive terminal
-1- and unbolt battery positive
cable from starter solenoid switch. |
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Unbolt earth cable from body. |
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Release catches -arrows- and
detach cover -1- for electronics
box in engine compartment. |
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Release catch using a screwdriver
-arrow- and detach cover -1-
for electronics box in engine compartment upwards. |
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Remove nut -arrow-, detach
electrical wiring and move clear. |
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Disconnect electrical connectors -1-
and -2-. |
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Remove selector mechanism from gearbox
→ Rep. gr.34. |
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Remove clutch slave cylinder
→ Rep. gr.30. |
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Remove selector lever cable, pull connector of mechatronic
off and remove all retainers from gearbox:
→ Rep. gr.34 |
| Continuation for all vehicles |
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Unscrew bolts -arrows- on
engine mounting approx. 2 turns. |
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Unscrew bolts -arrows- on
gearbox mounting approx. 2 turns. |
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Disconnect electrical connector -1-
on oil level and oil temperature sender -G266-. |
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Detach wire from retainer -2-. |
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Unscrew nuts for coupling rod -arrow-
on left and right from anti-roll bar. |
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Unscrew bolts -1, 2 and 3-, and
remove pendulum support. |
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Unscrew bolts -arrows- and
remove heat shield for right drive shaft. |
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Unscrew nuts -arrows- for
swivel joint on left and right. |
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If fitted, remove nut -arrow-
from front left vehicle level sender -G78-. |
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Detach swivel joint from transverse link on left and right. |
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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. |
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Swivel left suspension strut outwards and support it with
extension -2024 A /1- as shown in illustration. |
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Secure locking pin and swivel joint with locating pin
-arrow- and nut
-1-. |
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Secure swivel joint -2-
(right-side) to transverse link -1-
with nut -arrow-, as shown in
illustration. |
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Apply clamping piece T10497/2 at housing rib on cylinder
block, as shown in illustration. |
| Vehicles with four-wheel drive |
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Unbolt flexible coupling of propshaft from bevel box
→ Final drive, differential; Rep. gr.39. |
| Continuation for all vehicles |
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Position engine support T10497 with pin T10497/1 on cylinder
block. |
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Screw in bolt -1- through hole
“B” in engine support T10497 and tighten it to 20 Nm. |
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Fit adapter -T10497/3- to engine support -T10497- and
tighten bolt -1- to 20 Nm. |
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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. |
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Remove bolts -arrows- for
engine mounting. |
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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. |
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First lower engine/gearbox assembly slightly. |
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Then push gearbox end of engine/gearbox assembly forwards
and only then lower further. |
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Special tools and workshop equipment
required
Shackle -10 - 222 A /12-
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Separating engine and gearbox