VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation


Foltsvagen Golf 4
+ 1. Maintenance instruction
- 2. Engine
   - 2.1. Petrol engines
      2.1.1. Technical characteristics
      2.1.2. Removal and installation of the bottom mudguard of a motor compartment
      - 2.1.3. Engine 1,6-/1,8-I
         - 2.1.3.1. Power unit
            2.1.3.1.1. Removal
            2.1.3.1.2. Installation
         + 2.1.3.2. Gear belt
         + 2.1.3.3. Head of the block of cylinders of engines
      + 2.1.4. Engine 1,4-I
      + 2.1.5. The engine 2,3 - I-VR5
      2.1.6. Compression check in engine cylinders
      + 2.1.7. Removal and installation of a poliklinovy belt
      + 2.1.8. Recommendations about engine oils
      + 2.1.9. Circulation of engine oil
      2.1.10. Check of pressure of oil and sensor of pressure of oil
      2.1.11. Removal and installation of the oil pallet
      2.1.12. Engine start after major maintenance
      2.1.13. Diagnostics of malfunctions of the engine
      2.1.14. Main malfunctions of system of greasing
   + 2.2. Diesel engines
+ 3. Cooling system
+ 4. Fuel system
+ 5. Exhaust system
+ 6. Ventilation and heating system
+ 7. Coupling
+ 8. Transmission
+ 9. Suspension brackets and power shafts
+ 10. Steering
+ 11. Wheels and tires
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment and electroschemes



2.1.3. Engine 1,6-/1,8-I

2.1.3.1. Power unit

2.1.3.1.1 Removal

GENERAL INFORMATION

Arrangement of elements on the petrol engine 1,8-I Turbo

1–electric sockets of coils of ignition;
2–grounding tires;		 3–fuel nozzles;
4–vacuum hose

The engine together with a transmission acts in film from the car down from a motor compartment. At removal of the power unit it is necessary to use the crane. Also power unit can be lowered, using the special lift with holders of the engine.

To provide a sufficient workplace under the car, four goats or the automobile lift with a platform or a viewing hole are necessary to use.

Depending on process of manufacture and a car complete set in a motor compartment electric wires, pipelines and hoses can settle down differently. Therefore before a detachment of electric sockets and a rassoyedineniye of pipelines or hoses it is recommended to mark them a sticky tape.

Necessary special tools and supportive applications:

 – the crane for an engine raising;
 – a grip for tape collars;
 – load-lifting capture;
 – greasing on the basis of a molybdenum disulfide;
 – the dinamometrichesky key providing the moments of a tightening of 5-50 Nanometers;
 – the dinamometrichesky key providing the moments of a tightening of 40-200 Nanometers;
 – clip.

Prevention

All clips and collars which at removal of the engine unscrew or cut, it is necessary to establish at engine assembly on the same places therefore their assembly situation can be marked a sticky tape. At a detachment of electric sockets release fixing wire and after that disconnect the electric socket.

PERFORMANCE ORDER
1. Remove a weight wire from the accumulator.
Prevention

At a detachment of the accumulator contents of cells of memory, for example, a radio receiver code are erased. Without a code the manufacturer can connect a radio receiver again only.
2. Remove the storage battery.
3. Unscrew holders of the storage battery and remove them (nuts of fastening of the holder are specified by shooters).
4. Remove a starter.
5. Remove the case of the air filter.
6. Unscrew an air inlet going to the air filter.
7. Remove the bottom mudguard of a motor compartment.
8. Unscrew the left and right power shafts from a transmission flange. Using a soft wire, tie up the ends of power shafts to the stabilizer of cross-section stability or a body.
9. Merge cooling liquid from cooling system.
Engine 1,8-I Turbo
10. Remove the pipes, connecting a turbonagnetatel with a radiator of the air submitted under pressure, and the air filter. Weaken a tension and remove maple a belt.
11. Unscrew the pump of the amplifier of a steering from an arm and, using a soft wire, suspend it to a body. Do not disconnect hoses from the pump and do not bend hoses.
Cars with air central air
12. Unscrew top (And) and bottom (In) screws of fastening of the compressor of the conditioner and, without disconnecting from it hoses, move the compressor aside and fix it a soft wire.
Prevention

Do not disunite pipelines of central air of air.
13. Remove a reception exhaust pipe and the catalyst.
14. Remove submitting fuel hose.
15. Remove the top casing of the engine.
16. Disconnect electric sockets from coils of ignition and fuel nozzles. Unscrew the grounding tire (see fig. An arrangement of elements on the petrol engine 1,8-I Turbo).
17. Disconnect a vacuum hose from a pressure regulator (see fig. An arrangement of elements on the petrol engine 1,8-I Turbo).
18. Disconnect all vacuum hoses from the engine and a turbonagnetatel (the engine 1,8 - I - Turbo). If necessary before a detachment of hoses mark them.
19. Disconnect all electric sockets from the engine and a transmission.
20. Mark and disconnect submitting (1) and returnable (2) fuel hoses from the fuel highway.
21. Close the ends of fuel hoses a foil or suitable jams to exclude dirt hit in them.
22. Disconnect branch pipes of system of cooling from a radiator.
23. Disconnect from the engine and a body the hoses going to a broad tank, and move them aside.
24. Raise and fix a broad tank together with an arm.
Cars with a mechanical transmission
25. Disconnect the mechanism of switching and the working cylinder of coupling from a transmission.
Prevention

After removal of the working cylinder of coupling do not press a coupling pedal.
Cars with an automatic transmission
26. Unscrew the arms, fixing the delivery pipeline of the amplifier of a steering to a transmission. Disconnect a cable of management of an automatic transmission from the transmission lever.
27. In the lower part of a motor compartment unscrew bolts (are specified by shooters) and remove the pendular support supporting the engine and a transmission.
28. Lift the car so that the distance between the car and the earth made at least 60 see.
Removal of the power unit by the crane
29. Establish a wooden flooring in the sizes 30 x 40 of cm in thickness about 15 cm under the oil pallet of the engine.
30. Using the special adaptation, hook on the power unit for eyes for lifting of the power unit.
31. In the absence of special adaptations for support of the engine use a chain.
32. Raise the load-lifting mechanism so that the weight of the power unit was perceived by the load-lifting mechanism.
Engine removal by the special holder
33. The special holder represents the hydraulic VAG 1383А lift with the holder of the T10012 engine. Establish from below the special holder of the engine in an opening about the oil pallet and fix the engine nuts, having tightened them the moment of 25 Nanometers. Raise the holder of the engine so that the weight of the power unit was perceived by the holder.
34. Unscrew bolts (are specified by shooters), fixing the right top support of the power unit.
35. Unscrew bolts (are specified by shooters) and remove the left support of the power unit.
36. Check that all electric sockets and the hoses connecting the engine and a transmission to a body are disconnected.
37. At engine removal with use of the crane move the power unit forward and, being careful, lower it on a wooden support. Fix the power unit so that to exclude its capsizing.
38. If necessary disconnect a transmission from the engine.