Engine dismantling (VW Golf 1)

Preparatory work

The engine together with the gearbox is pulled out upwards. This will require a pulley block that can be stably installed at a sufficient height. It is also advisable to have an assistant nearby. Before doing this work, look at the illustrations showing the engine compartments to know where the corresponding parts are located. For cars manufactured after August 1979, you must purchase the necessary special tool to dismantle the exhaust manifold, otherwise dismantling the engine will not be successful when removing the exhaust system. See chapter "Turbocharger".

Dismantling

Remove the engine hood (see chapter "Body").

Remove the wires from the battery.

Drain the coolant (see chapter "Cooling system").

Remove the water hose from the front at the cylinder head fitting, also remove the hoses between the engine, radiator, heater and expansion tank.

Disconnect the plug connections at the radiator fan and at the thermal switch.

Unscrew the radiator fixing screws (see chapter "Cooling system").

Remove the radiator together with the fan, support ring and pneumatic guides.

Disconnect the fuel filter from the body and place it next to the washer reservoir.

Disconnect the fuel supply and drain line clamps at the fuel pump.

Disconnect the accelerator rod near the high pressure fuel pump lever; completely detach the retaining clip.

For a car with an automatic transmission, remove the accelerator rod holder at the fuel pump or at the cylinder head. Make sure that its installation does not change.



Remove the cold start accelerator rod (see section "Replacing the cold start accelerator rod").

Remove the electrical cable or disconnect the plug connections at the following devices: generator, fuel pump switch, glow plugs, oil pressure sensor, temperature sensor and thermal switch.

Remove the generator (see section "Dismantling the generator").

Remove the electrical wires from the starter.

Remove the starter (see section "Removal the starter" in the chapter "Starter").

Remove the limiters completely (torsional load bearing) near the oil filter.

Replace the clutch rod (see section "Replacing the clutch rod").

Disconnect the speedometer shaft from the gearbox. Close the hole in the gearbox with a rubber plug to prevent oil from leaking out.

Remove the vacuum hose leading to the brake booster and the hose at the vacuum pump.

Remove the connecting rod, control rod and rotary lever of the gearshift system (see chapter "Gearbox and final drive").

Set the automatic transmission control lever to position "P".

Raise the front of the car onto supports.

Disconnect the outlet pipe from the holder near the gearbox.

Remove the front exhaust pipe from the exhaust elbow (see section "Dismantling the exhaust pipe").

Remove the wire from the reverse switch on the gearbox.

On the right and left side of the gearbox, disconnect the axle shafts and hang them near the body using wire (see section "Disassembling the drive shaft").

For an automatic transmission, disconnect the control lever cable clamps, remove the accelerator pedal cable, and also the cable bracket.


At the rear, unscrew the shift mechanism supports from the body and from the gearbox housing. Remove the supports.

Lower the car.

Pull two chains or sufficiently strong cables through the eyes on the right and left of the engine and secure them to the pulley block.

Slightly lift the engine and gearbox block so that it is under slight tension.

Remove the engine mount fixing bolt.

Remove the gearbox support on the left.

Carefully remove the shift mechanism assembly (with slight rotation).

When lifting the engine, guide it manually to avoid damaging anything.