Volkswagen Golf / Golf Plus. Manual - part 291

 

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Volkswagen Golf / Golf Plus. Manual - part 291

 

 

Removing and installing engine

Removing engine 

⇒ page 2

Securing engine to assembly stand 

⇒ page 7

Notes on installing 

⇒ page 7

 .

Assembly mountings 

⇒ page 10

 .

1.1

Removing engine

Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐

port -VW 540-

♦ Workshop crane -V.A.G

1202 A-

♦ Drip tray -V.A.G 1306-

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

2

     Rep. Gr.10 - Removing and installing engine

 

♦ Torque wrench -V.A.G

1332-

♦ Engine and gearbox jack -

V.A.G 1383 A-

♦ Spring-type clip pliers -VAS

5024-

♦ Stepladder -VAS 5085-
♦ Guide rods -T10093-
♦ Cable ties

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.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Removing and installing engine    

3

 

ment, pay attention to the following due to the cramped condi‐

tions:

♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐

vated charcoal filter system, coolant, refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

sitions.

♦ 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 fas‐

tening -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 up‐

wards at -arrows-.
– Remove plenum chamber bulkhead. ⇒  General body repairs,

exterior; Rep. Gr.  50 ; Body - front, plenum chamber bulk‐

head .

– Remove air filter housing with air mass meter and connecting

pipe.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

4

     Rep. Gr.10 - Removing and installing engine

 

– Remove battery and battery tray.
– Disconnect fuel supply and return lines as well as coolant line

on cylinder head.

WARNING

♦ The fuel and the fuel lines in the fuel system can become

very hot (danger of scalding)!

♦ The fuel system is also under pressure! Before opening

the system, place cloths around the connections. Then

carefully loosen connection to release the pressure!

♦ Wear eye and hand protection when performing any type

of repair work on the fuel system!

– Remove insulation tray ⇒  General body repairs, exterior; Rep.

Gr.  50 ; Body - front; Assembly overview

– Bring lock carrier into service position ⇒  General body repairs,

exterior; Rep. Gr.  50 ; Body - front; Lock carrier - service po‐

sition .

– Drain coolant 

⇒ page 102

 .

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 re‐

frigerant circuit:
– Remove poly V-belt 

⇒ page 13

 .

– Remove air conditioner compressor ⇒  Heating, air condition‐

ing; Rep. Gr.  87 ; Removing and installing compressor brack‐

et .

– Secure air conditioner compressor to lock carrier so that re‐

frigerant lines are free of stress.

– Remove alternator ⇒  Electrical system; Rep. Gr.  27 ; Re‐

moving and installing alternator and poly V-belt .

Continuation for all vehicles
– Remove connecting pipes between charge air cooler and en‐

gine.

– Unbolt left and right-hand drive shafts from gearbox ⇒  Run‐

ning gear, axles, steering; Rep. Gr.  40 ; Removing and

installing drive shaft .

– Remove front exhaust pipe 

⇒ page 186

 .

– Release connectors on engine control unit and pull them off.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Removing and installing engine    

5

 

 

 

 

 

 

 

 

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