VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation


Foltsvagen Golf 4
+ 1. Maintenance instruction
- 2. Engine
   + 2.1. Petrol engines
   - 2.2. Diesel engines
      2.2.1. Technical characteristics
      2.2.2. Bottom mudguard of a motor compartment
      2.2.3. Removal and installation of the power unit
      + 2.2.4. Gear belt
      2.2.5. Removal and installation of an inlet collector of the diesel SDI engine
      2.2.6. Compression check in engine cylinders
      2.2.7. Removal and installation of a poliklinovy belt
      2.2.8. Recommendations about engine oils
      2.2.9. Circulation of engine oil
      2.2.10. Check of pressure of oil and sensor of pressure of oil
      2.2.11. Removal and installation of the oil pallet
      2.2.12. Diagnostics of malfunctions of the diesel engine
      2.2.13. Main malfunctions of system of greasing
+ 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





2.2.3. Removal and installation of the power unit
GENERAL INFORMATION

Fuel filter of diesel engines

 1–spring bracket;

2–gate;

3–fuel branch pipe;

4–fuel branch pipe

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.

Removal

PERFORMANCE ORDER
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.
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 (shooters specified nuts of fastening of the holder of the storage battery).
4. Remove a starter.
5. Remove the bottom mudguard of a motor compartment.
6. 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.
7. Merge cooling liquid from cooling system.
TDI engine
8. Remove a pipe connecting a radiator of nadduvayemy air and an inlet collector.
SDI engine
9. Remove a pipe connecting a radiator of nadduvayemy air and the air filter.
10. Weaken a tension and remove poliklinovy a belt.
Remove a starter.
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 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 (And – the top bolt, In – the bottom bolt).
Prevention

Do not disunite pipelines of central air of air.
13. Remove a reception exhaust pipe and the catalyst.
14. Weaken collars, mark and disconnect from a turbonagnetatel a vacuum hose and an air inlet branch pipe.
15. Disconnect all electric sockets from the engine and a transmission.
16. Release a spring bracket (1) (see fig. The fuel filter of diesel engines) also remove knot with hoses from the gate (2). Weaken collars, and remove fuel hoses from unions (3 and 4). Close the ends of fuel hoses a foil or suitable jams to exclude dirt hit in them.
17. Disconnect from a partition of a motor compartment hoses of supply of cooling liquid to a heater radiator.
18. Disconnect from the engine and a body the hoses going to a broad tank, and move them aside.
19. Disconnect branch pipes of system of cooling from a radiator.
20. Raise and fix a broad tank together with an arm.
Cars with a mechanical transmission
21. 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
22. 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.
23. 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.
24. 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

PERFORMANCE ORDER
1. Establish a wooden flooring in the sizes 30 x 40 of cm in thickness about 15 cm under the oil pallet of the engine.
2. Using the special adaptation, hook on the power unit for eyes for lifting of the power unit.
3. In the absence of special adaptations for support of the engine use a chain.
4. 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

The special holder represents the hydraulic VAG 1383А lift with the holder of the T10012 engine.

PERFORMANCE ORDER
1. 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.
2. Unscrew the bolts, fixing the right top support of the power unit (are specified by shooters).
3. Unscrew bolts (are specified by shooters) and remove the left support of the power unit.
4. Check that all electric sockets and the hoses connecting the engine and a transmission to a body are disconnected.
5. 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.
6. If necessary disconnect a transmission from the engine.

Installation

PERFORMANCE ORDER
1. Check a condition of support of the power unit and hoses on existence of cracks or wear and, if necessary, replace them.
2. If the transmission was disconnected from the engine, check a coupling condition.
3. Establish the power unit in a motor compartment and level it as follows.
4. Fix the right support of the power unit new bolts, having tightened them at this stage by hand.
5. Fix a pendular support of the power unit new bolts, having tightened them at this stage by hand.
6. Tighten support of the power unit the demanded moment (see tab. Inhaling moments).
Prevention

If it is not specified, the standard moments of a tightening of bolts the following: М8 – 20 Nanometers, М10 – 45 Nanometers and М12 – 60 Nanometers.
7. If the compressor acted in film, fix it bolts, having tightened them the moment of 45 Nanometers.
8. Establish сервонасос.
9. Establish a starter.
10. Establish poliklinovy a belt and adjust its tension.
Diesel TDI engine
11. Establish a pipe connecting a radiator of nadduvayemy air and an inlet collector, and fix it collars.
Diesel SDI engine
12. Establish a pipe connecting an inlet collector and the air filter.
13. Establish a reception exhaust pipe and the catalyst with new laying.
14. Establish the right and left power shafts.
15. Connect hoses of supply of cooling liquid to a heater radiator on a partition of a motor compartment and fix them collars.
16. Establish the radiator fan.
Cars with a mechanical box
17. Connect drafts of switching for a transmission. Establish the working cylinder of coupling.
Cars with an automatic transmission
18. Establish and fix on a transmission an arm for the delivery pipeline of the amplifier of a steering. Connect to a transmission a cable of management and adjust it.
19. Connect to the power unit the disconnected electric sockets and pipelines, having fixed them collars.
20. Connect fuel hoses to branch pipes (3 and 4, see fig. Fuel filter of diesel engines) fuel filter. The arrow on the fuel filter specifies the direction of a stream of fuel.
21. Establish on a place and fix the holder of the storage battery.
22. Establish into place the storage battery, but at this stage do not connect to it a weight wire.
23. Establish into place the gate (2) and fix it a spring bracket (1, see fig. Fuel filter of diesel engines).
24. Check correctness of connection of electric sockets and pipelines to the power unit.
25. Check oil level in the engine and a transmission and if necessary finish it to norm.
26. Fill in in cooling system cooling liquid.
27. Establish the top casing of the engine.
28. Establish the bottom mudguard of a motor compartment.
29. Connect a weight wire to the accumulator.
Prevention

Make active window regulators with an electric drive, and also establish time on hours and enter a code into a radio receiver.
30. Start and warm up the engine to normal working temperature.
31. Check level of oil and cooling liquid and tightness of all connections.
32. Visually check correctness of adjustments.

Inhaling moments

Junctions
Inhaling moments
The engine to an arm
60 Nanometers + to tighten on a corner 90 °
Transmission to an arm
60 Nanometers + to tighten on a corner 90 °
Pendular support to a transmission
40 Nanometers + to tighten on a corner 90 °
Pendular support to a body
20 Nanometers + to tighten on a corner 90 °