VOLKSWAGEN GOLF IV

since 1997 of release

Repair and car operation



Foltsvagen Golf 4
+ 1. Maintenance instruction
+ 2. Engine
+ 3. Cooling system
+ 4. Fuel system
+ 5. Exhaust system
+ 6. Ventilation and heating system
+ 7. Coupling
- 8. Transmission
   - 8.1. Removal and transmission installation
      8.1.1. Engines 1,8/1,9/2,3-I
      8.1.2. Engines 1,4/1,6-I
   8.2. Removal and installation of an automatic transmission
   8.3. Gear shifting mechanism
   8.4. Removal and installation of the case of the lever of gear shifting
   + 8.5. Adjustment of cables of gear shifting
   8.6. Full automation
   + 8.7. Adjustment of draft of a cable of the lever of gear shifting
+ 9. Suspension brackets and power shafts
+ 10. Steering
+ 11. Wheels and tires
+ 12. Brake system
+ 13. Body
+ 14. Electric equipment and electroschemes


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8.1.1. Engines 1,8/1,9/2,3-I

GENERAL INFORMATION

Arrangement and the moments of a tightening of bolts of fastening of a transmission on models with engines 1,8-/1,9

And, In – an arrangement of aligning plugs

1
M 12 x 55
80 Nanometers
2
M 12 x 150
80 Nanometers
3
M 10 x 50
40 Nanometers
4
M 7 x 12
10 Nanometers
5
M 7 x 12
10 Nanometers

Arrangement and the moments of a tightening of bolts of fastening of a transmission on models with engines 2,3-I

And, In – an arrangement of aligning plugs
1
M 12 x 55
80 Nanometers
2
M 12 x 55
80 Nanometers
3
M 12 x 65
80 Nanometers
4
M 12 x 70
40 Nanometers
5
M 10 x 60
10 Nanometers

Removal

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 case of the air filter.
3. Disconnect electric sockets from the sensor of a tachometer (1) and the switch of light of a backing (2).
4. Unscrew an emphasis (And) and cable fastening (In) from the gear shifting lever. Unscrew draft of a choice of transfers from the lever (C) and turn it in the arrow direction.
5. Release a spring clamp and take a coupling hose from an arm on a transmission. Unscrew bolts and remove an arm of support of cables of management of a transmission from a transmission.
6. Unscrew two bolts and remove from a transmission the working cylinder of coupling. Using a soft wire, suspend the working cylinder of coupling to a body, without disconnecting from it a hose. At the removed working cylinder of coupling do not press a coupling pedal.
7. Unscrew a nut (1) and disconnect the grounding tire from the power unit. Unscrew the holder (3) wires of a starter and move it aside. Unscrew a nut (2) on a starter.
8. Unscrew all bolts of fastening of a transmission available from above to the engine.
9. Using the load-lifting mechanism or the special VW 10-222A adaptation, raise the power unit so that the weight of the power unit was perceived by the load-lifting adaptation.
10. Lift cars and remove the bottom mudguard of a motor compartment.
11. Remove a starter.
12. Unscrew an arm of the amplifier of a steering from a transmission case.
13. At existence remove a safety cap for the right sharnirny flange (A) of a power shaft. Unscrew a bolt (the top arrow) fastenings of a small partition behind the right power shaft and remove a partition.
14. Unscrew hinges of power shafts from a transmission. Using a soft wire, tie up power shafts as it is possible above to a body. Thus do not scratch a varnish covering of power shafts.
15. Disunite an exhaust system between the catalyst and the average exhaust silencer.
16. Unscrew holders of a reception exhaust pipe from a transmission. If necessary remove a reception exhaust pipe.
17. Unscrew the bolts, fixing the bottom pendular support of the power unit.
18. Unscrew bolts (And), then bolts (In) fastenings of the left support of the power unit.
19. Unscrew a support (And) transmissions from a transmission.
20. In the lower part establish the special tool 457/1 (C) and fix it a bolt of M 8х25 (In) in an opening for fastening of a pendular support. Fix the squeezing device 3300А (And) two bolts (are specified by shooters). Rotating the screw of the squeezing device, move a transmission forward.
21. In the absence of the special squeezing device it is possible to use an automobile jack.
22. Support a transmission the lift with special captures of VW 3282. It is alternatively possible to support a transmission an automobile jack through wooden whetstone.
23. Unscrew the bottom bolts of fastening of a transmission to the engine.
24. Move a transmission from the engine and lower it down. When lowering a transmission do not damage hoses of system of the amplifier of a steering.

Installation

PERFORMANCE ORDER
1. At replacement of a transmission establish on a new transmission removed from an old box the sensor of speed and choice levers, and gear shiftings.
2. Check a coupling condition.
3. Clear shlitsevy connection of a power shaft of a transmission and grease with a thin layer of greasing on the basis of a molybdenum disulfide. Check that the coupling disk smoothly moves on driving to a transmission shaft.
4. Check that in the block of cylinders of the engine directing plugs for a transmission centering are established.
5. Move the lever of switching off of coupling to a case of a transmission and fix it in this situation by a bolt of M 8х35. After installation of a transmission unscrew a bolt.
6. In the horizontal plane move a transmission to the engine, thus the power shaft of a transmission should enter into a coupling disk. If the power shaft does not enter in a shlitsa of a disk of coupling, for a flange for a power shaft turn transmission shaft in the relevant situation.
7. Supporting a transmission hands, remove the adaptation for transmission support.
8. Screw in the bottom bolts of fastening of a transmission to the engine and bolts of fastening of a starter.
9. Unscrew the bolt of M 8х35 fixing the lever of switching off of coupling in a case of a transmission. In an opening then the bolt of fastening of an arm of cables of gear shifting is screwed in.
10. Screw in and tighten by hand bolts of fastening of the left support of the power unit and the load-lifting mechanism transfer the power unit to assembly situation.
11. Tighten bolts (And) fastenings of the left support of the power unit to a body the moment of 25 Nanometers. Screw in new bolts (In) fastenings of the left support of the power unit and tighten them by hand.
12. Screw in new bolts of fastening of a pendular support and tighten them by hand.
13. Remove the load-lifting mechanism supporting the engine.
14. Moving the power unit aside, establish it in normal situation on support of the power unit.
15. Tighten bolts of fastening of support of the power unit the demanded moment, then tighten them on 90 °.
16. Connect to a transmission power shafts.
17. Establish a big and small partition of power shafts.
18. Screw in bolts of fastening of a pendular support of the power unit and tighten them the moment of 50 Nanometers.
19. Establish a starter.
20. Establish the holder of cables of gear shifting and screw it on a box, having tightened bolts the moment of 25 Nanometers.
21. Screw cable fastening on the lever of gear shifting and tighten a bolt of fastening the moment of 25 nanometers.
22. Establish a cable of a choice of transfers on the lever and fix it a spring clip.
23. Adjust draft of gear shifting.
24. Screw up an emphasis of the lever of gear shifting and tighten a bolt of fastening the moment of 25 Nanometers.
25. Connect electric sockets to a transmission.
26. Connect wires to a starter.
27. Grease a pusher of the working cylinder of coupling with greasing on the basis of a molybdenum disulfide. Establish the working cylinder of coupling and fix it bolts, having tightened them the moment of 20 Nanometers.
28. Several times press a pedal of coupling and check coupling work. If the hydraulic contour of coupling was disunited, remove from it air.
29. Establish a reception exhaust pipe with the catalyst with new consolidation.
30. Establish and screw on a transmission case an arm of the amplifier of a steering.
31. Check an oil condition in a transmission.
32. Establish the bottom mudguard of a motor compartment.
33. Establish the case of the air filter.
34. Connect a weight wire to the accumulator.

Boltovoye connection
Engines 1,8-/1,9-/2,3-I
The engine to the holder
60 Nanometers + 90 °
Transmission to the holder
50 Nanometers + 90 °
The holder to a body
60 Nanometers + 90 °
Support to a transmission
40 Nanometers + 90 °
Support to a body
20 Nanometers + 90 °