Volkswagen Golf/Jetta 2 manual

Engine - removal
Engine repair procedures - 1.05 and 1.3 litre pre August 1985 / Engine - removal


1 Disconnect the battery negative lead.

2 Remove the bonnet.

3 Drain the engine coolant and remove the radiator, complete with cooling fan unit.

4 Remove the air cleaner unit.

5 Loosen the clip and disconnect the top hose from the thermostat housing.

6 Place a container beneath the engine then unscrew the sump drain plug and drain the oil - see Chapter 1. When complete, clean the drain plug and washer and refit it to the sump.

7 Identify the fuel supply and return hoses then disconnect them from the fuel pump (see illustration) and fuel reservoir/carburettor.

Plug the hoses to prevent fuel leakage.

5.7 Detach hoses from fuel pump
5.7 Detach hoses from fuel pump

8 Loosen the clip and disconnect the bottom hose from the coolant pipe at the rear of the engine.

9 Disconnect the accelerator cable and, where applicable, the choke cable.

10 Disconnect the heater hoses from the thermostat housing and rear coolant pipe.

11 Detach the following connections, identifying each lead as it is disconnected to avoid confusion on reassembly: a) The oil pressure switches on the rear (carburettor side) of the cylinder head b) Inlet manifold preheating element line connector
c) Thermo-switch leads (coolant hose intermediate piece)
d) Distributor HT and LT leads e) Starter motor
f) Temperature sender unit (thermostat housing)
g) Fuel cut-off solenoid valve on carburettor h) Earth strap to gearbox 12 Detach the wiring loom from the location clip on the bottom hose and fold back out of the way.

13 Disconnect and unclip the vacuum hoses from the distributor and inlet manifold as necessary.

14 Disconnect the clutch cable (see illustration).

5.14 Earth lead (A) and clutch cable (B)
5.14 Earth lead (A) and clutch cable (B)

15 Disconnect the exhaust downpipe from the exhaust manifold.

16 Disconnect the speedometer cable from the gearbox and place it on one side.

17 Apply the handbrake then jack up the front of the vehicle and support it on axle stands (see УJacking and vehicle supportФ).

18 Remove the screw from the shift rod coupling and ease the coupling from the rod (see illustration). The screw threads are coated with a liquid locking agent and if difficulty is experienced, it may be necessary to heat up the coupling with a blowlamp whilst observing the necessary fire precautions.

5.18 Shift rod coupling screw
5.18 Shift rod coupling screw

Note that once removed this screw should be renewed.

19 Note its orientation then withdraw the shift rod coupling.

20 Unbolt the exhaust steady bracket from the downpipe and clutch housing/starter motor.

21 Detach the reversing light switch lead (see illustration).

5.21 Reversing light switch
5.21 Reversing light switch

22 Unbolt the driveshafts from the drive flanges and tie them to one side with wire.

23 Attach a suitable hoist to the engine lifting eye brackets (one at each end of the cylinder head on the carburettor side) (see illustration). Take the weight of the engine/gearbox unit.

5.23 Engine lifting eye
5.23 Engine lifting eye

24 Working from above, undo the three engine mounting/bearer retaining bolts (underneath the carburettor) (see illustration).

5.24 Engine mounting/bearer - right-hand
5.24 Engine mounting/bearer - right-hand

25 Undo and remove the gearbox mounting bolt (rear left side of engine compartment).

26 Undo and remove the front engine mounting bolt and then remove the bolts securing the bracket to the engine. Withdraw the mounting (see illustrations).

5.26a Undo front mounting through-bolt
5.26a Undo front mounting through-bolt

5.26b Unbolt and remove mounting unit
5.26b Unbolt and remove mounting unit

27 Before lifting out the engine/gearbox unit, get an assistant to hold the engine steady and help guide it clear of surrounding components as it is removed.

28 Lift the engine/gearbox unit from the engine compartment (see illustration) while turning it as necessary to clear the internally mounted components. Make sure that all wires, cables and hoses have been disconnected.

5.28 Lifting out engine/gearbox unit
5.28 Lifting out engine/gearbox unit

29 Lower the unit onto a workbench or large piece of wood placed on the floor.


© 2018 www.vwgolfjetta2.ru. All Rights Reserved.