Volkswagen Golf / Golf Plus. Manual - part 292

 

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Volkswagen Golf / Golf Plus. Manual - part 292

 

 

– Pull off or disconnect all other electrical connections from en‐

gine and gearbox as necessary and lay to side.

– Separate all connecting, coolant, vacuum and intake hoses

from engine.

Vehicles with manual gearbox
– Remove slave cylinder for hydraulic clutch. ⇒  6-speed manual

gearbox 02S; Rep. Gr.  30 ; Repairing clutch mechanism; As‐

sembly overview - hydraulics .

– Unbolt gear selector mechanism from gearbox. ⇒  6-speed

manual gearbox 02S; Rep. Gr.  34 ; Repairing selector mech‐

anism .

Vehicles with four-wheel drive:
– Remove selector mechanism from gearbox ⇒  6-speed man‐

ual gearbox 02Q, four-wheel drive; Rep. Gr.  34 ; Repairing

selector mechanism .

– Separate pressure line for hydraulic clutch control.
– Remove front propshaft ⇒  Final drive 02D, 0AV; Rep. Gr.  39 ;

Assembly overview - repairing propshaft .

Continuation for all vehicles:

– Unbolt pendulum support -arrows-.
Vehicles with particulate filter
– Remove subframe ⇒  Running gear, axles, steering; Rep. Gr. 

40 ; Removing and installing subframe .

– Remove right drive shaft ⇒  Running gear, axles, steering;

Rep. Gr.  40 ; Removing and installing drive shafts .

– Remove steering box ⇒  Running gear, axles, steering; Rep.

Gr.  48 ; Removing and installing steering box .

Continuation for all vehicles:

– Insert engine bracket -T10012- in engine and gearbox jack -

V.A.G 1383 A- .

Note

Support pins must be secured to engine bracket -T10012- as

shown.

– Fit engine bracket -T10012- to cylinder block with M10 x 25/

8.8 bolt and tighten to approx. 40 Nm.

– Raise engine and gearbox slightly using engine and gearbox

jack -V.A.G 1383 A- .

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

6

     Rep. Gr.10 - Removing and installing engine

 

Note

To remove securing bolts, use stepladder -VAS 5085- .

– Unbolt assembly mounting on gearbox side from gearbox

bracket -arrows-.

– Carefully lower engine with gearbox.

Note

Engine with gearbox must be guided carefully when lowered to

prevent damage to bodywork.

1.2

Securing engine to assembly stand

When working on the engine, secure it to support clamp -VW 313-

of the assembly stand using engine and gearbox support -VW

540- .
Procedure
– Disconnect gearbox.
– Attach lifting tackle -2024 A- as shown and raise engine out of

engine and gearbox jack -V.A.G 1383 A- using workshop hoist

-V.A.G 1202 A- .

Pulley end: 2nd hole in hook rail at position 1
Flywheel end: 4th hole in hook at position 8

WARNING

The hooks and locating pins must be secured with locking pins.

Note

The positions marked 1...4 on the bar must be towards the

pulley end.

The holes in the hook rails are counted up from the hook.

– Secure engine on support clamp -VW 313- using engine and

gearbox jack -VW 540- .

1.3

Notes on installing

Installation is carried out in the reverse order. When installing,

note the following:

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

1. Removing and installing engine    

7

 

When installing engine, ensure correct position of assembly

mountings:
– On belt pulley side, ensure that there is a distance -a- of at

least 10 mm between engine support and right longitudinal

member.

– The side surface of the engine support -2- should be located

parallel to the support arm -1-. Dimension -x- must be identical

at top and bottom.

Note

Distance -a- = 10 mm can also be checked with a metal rod of

suitable size, or similar.

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

8

     Rep. Gr.10 - Removing and installing engine

 

Dimension -x- must be identical at top and bottom.

Note

Torque specifications for assembly mounting 

⇒ page 10

 .

Electrical connections and routing. ⇒  Electrical system; Rep.

Gr.  97

– Install pendulum support.
– Install drive shafts ⇒  Running gear, axles, steering; Rep. Gr. 

40 ; Removing and installing drive shafts .

– Install front exhaust pipe 

⇒ page 186

 .

Vehicles with manual gearbox
– Install slave cylinder for hydraulic clutch ⇒  6-speed manual

gearbox 02S; Rep. Gr.  30 ; Repairing clutch mechanism; As‐

sembly overview - hydraulics .

– Remove selector mechanism from gearbox ⇒  6-speed man‐

ual gearbox 02S; Rep. Gr.  34 ; Repairing selector mecha‐

nism .

Vehicles with four-wheel drive:
– Install selector mechanism on gearbox ⇒  6-speed manual

gearbox 02Q, four-wheel drive; Rep. Gr.  34 ; Repairing se‐

lector mechanism .

– Install pressure line for hydraulic clutch control.
– Install front propshaft ⇒  Final drive 02D, 0AV; Rep. Gr.  39 ;

Assembly overview - repairing propshaft .

Continuation for all vehicles:
– On vehicles with particulate filter install subframe ⇒  Running

gear, axles, steering; Rep. Gr.  40

– Install alternator ⇒  Electrical system; Rep. Gr.  27 ; Removing

and installing alternator and poly V- belt .

– Install air conditioner compressor ⇒  Heating, air conditioning;

Rep. Gr.  87 ; Removing and installing compressor bracket.

– Install poly V-belt 

⇒ page 13

 .

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

Gr.  50 ; Body - front; Assembly overview.

– Install engine control unit 

⇒ page 178

 .

– Install plenum chamber bulkhead ⇒  General body repairs,

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

head .

– Fill cooling system with coolant 

⇒ page 102

 .

– Carry out road test and then read fault memory 

⇒ page 178

 .

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

1. Removing and installing engine    

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