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

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     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    

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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

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     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    

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