Removal and installation the engine (VW Golf 3)

The engine is pulled out upwards together with the gearbox. To do this, you will need a lift that you can hang stably at the required height.

It is recommended to carry out this work with an assistant. Before work, look at the picture of the engine compartment so that you know where the parts described are located.

Since the Golf model has a large number of electrical wires and vacuum hoses, you must first mark all their connection points in order to install them correctly.

Removal

Remove the battery.

Remove the engine hood.

On vehicles with air conditioning, do not open the coolant line!

Since the compressor is removed when there is an air conditioning system, it must be secured together with the closed hoses on the front side of the car in such a way that the hoses are not under tension.



Unscrew the air conditioning fluid reservoir and leave it hanging freely.

Remove the front of the vehicle. If the vehicle has an air conditioning system, the front of the vehicle must be placed on a crossbar due to the coolant hoses and secured with wire to prevent it from rolling away.



Remove the air filter housing together with the front and rear suction hoses from the engine.

Separate the central plug of the engine. To do this, hold the narrow part of the plug (arrow) and turn the wide ring.

Remove the cable plugs from the reverse light switch and the tachometer sensor.

Loosen the ground connections on the gearbox and pull it out.

Hang the gas rod on the fuel injection pump lever and on the stop. Insert the safety cover back into the cut (maintains adjustment during assembly).

Disconnect the cold start acceleration rod from the fuel injection pump.

Close the connection point on the high-pressure fuel pump again with a wooden plug.

Remove the hose between the vacuum pump and the brake booster.

Disconnect the clutch rod from the lever and set it aside.

Loosen the two bolts on the servo pump tensioner.




Loosen the three mounting bolts of the pivot arm and remove the V-belt.

Set the power steering pump and plugged hoses aside.

Drain the coolant.

Remove all coolant hoses between the radiator, heating system heat exchanger, engine and expansion tank.

For vehicles with automatic transmission, remove the notched V-belt.

Remove the shock absorber and water pump pulley.

Stop the car from the front.

Remove the shift rod and the short rod of the gearshift lever. To do this, on the long rod on the left in the direction of travel, pull the clamping lever on the plastic head with a screwdriver, pull the hose away from the head.

On an automatic transmission, set the gearshift lever to position "P" and remove the rod from the transmission.

Unscrew the front wheel drive cardan shafts on the right and left of the gearbox and tie them to the body with wire.

Unscrew the counterweight from the aggregate beam.

If present, unscrew the heat shield for the inner joint of the right cardan shaft.

Unscrew the exhaust pipe from the exhaust manifold.

"Let go" of the car.

Disconnect the ABS sensor plug connection on the right engine console (anti-lock braking system).

Unscrew the bolt between the right engine console and the rubber-metal support.

Release the gearbox console from the rubber-metal support.

Raise the engine/gearbox assembly slightly (power unit).

Remove the crankcase.

Remove the bolt from the top of the front rubber-metal support.

Pass two chains or suitable steel cables through the axles on the right and left of the engine and attach them to the hoist.

Unscrew the supports and gearbox consoles.

Gently pull out the power unit by turning it slightly.

When lifting the engine, carefully guide it by hand so that engine or body parts do not interfere with lifting.

Loosen the engine mounting bolts to the gearbox.

Separate the engine from the gearbox by pressing, for example, with a crowbar.

Installation

All work is carried out in reverse order.

Replace all self-locking nuts.

Check whether the guide bushings are inserted into the cylinder block - they serve to center the engine and gearbox.



Bolt the engine to the gearbox

Bolt tightening torques:

• 1 - 80 Nm (M12x55)
• 2 - 10 Nm (M6x8)
• 3 - 10 Nm (M7x12)
• 4 - 80 Nm (M12x64)
• 5 - 60 Nm (M10X140)

Arrows indicate guide bushings for centering the engine and gearbox.

Lower the power unit into the vehicle.

When installing the engine mounts, the recess on the front and rear suspension console must fit into the clamping pin of the rubber-metal mount.

Align the power unit with shaking movements, tighten the screw connections.

Depress the clutch pedal at least five times all the way.

Press the attached control lever approximately 10 mm in the opposite direction to its direction of movement; it should move freely.

It is necessary to adjust the throttle, gear shifting, idle speed and, after installing the front part of the car, the lighting devices.

Tightening torques