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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Golf IV (1997 release)

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Volkswagen Golf 4
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Golf 4
Instructions
Engine
Gasoline engines
Technical specifications
Removal and installation of the bottom mudguard of a motor compartment
Engine 1,6- / 1,8-I
Powertrain
Toothed belt
The cylinder head engines
Withdrawal
Preparation for the installation of the head
Setting
Checking the hydraulic valve lifters
Repair of the cylinder head
The engine 1,4-I
Engine-I 2,3-VR5
Compression check in engine cylinders
Removing and installing V-ribbed belt
Engine oil recommendations
Circuit of motor oil
Checking oil pressure and oil pressure sensor
Removing and installing oil pan
Starting the engine after major repairs
Troubleshooting Engine
The basic malfunctions of system of greasing
Diesel engines
Cooling system
Fuel System
Exhaust system
Ventilation and heating system
Coupling
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Suspension brackets and power shafts
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Withdrawal



Location of fixing the air pipe and turbocharger thermofilter

1 - bolt thermofilter;

2 - bolt the air tube;

3 - the bolt of the air tube;

4 - a collar;

5 - bolt thermofilter

PERFORMANCE ORDER
1. Check that the engine is cold, otherwise allow time for cooling of the engine.
2. Turn off the ignition and remove a wire of weight from the accumulator.

A warning

When disconnecting the battery clears the memory cells, for example, a radio receiver code. Without the code, the radio can reconnect only to the manufacturer.


3. Drain the cooling system of the engine coolant.
4. Clean the spark plug, using a brush, vacuum cleaner or a jet of compressed air to prevent dirt from entering the engine cylinders after removing spark plugs. Remove the spark plug using the spark plug spanner.
5. Remove the air filter.
6. Remove the pressure in the fuel system.
7. To relieve the pressure in the fuel system, wrap the connection of fuel hoses and, being careful, slowly loosen the connection, while gradually the fuel pressure decrease.
8. Mark and disconnect submitting and returnable fuel hoses from the fuel distributor. Before disconnecting the hose, loosen the clamps and move them to the hoses.
9. Close the end of the fuel hoses suitable stoppers.
10. Disconnect electric sockets from fuel atomizers and move them aside.
11. Mark and disconnect from the cylinder head all the electrical connectors.
12. Remove the nuts (indicated by arrows), fastening the top of the inlet pipe to the bracket (shows the location of the screws on the engine 125 hp).
13. Remove the nuts (arrows) securing the intake manifold to the cylinder head.
Engine 1,6-I
14. Disconnect the electrical connector (1) from the shift valve inlet pipe. Disconnect the hose (2) from the pressure regulator.
15. The arrow shows the direction of disengagement of the inlet pipeline.
16. Remove the bracket (arrow) the bottom of the inlet tube to the cylinder head.
17. Mark and disconnect from the cylinder head coolant hoses.
18. Remove a reception exhaust pipe with catalyst from the elbow.
The engine 1,8-I- Turbo.
19. Loosen the clamp (4), loosen the screws (2, 3) supporting pipe turbocharger. Remove the screws (1 and 5), fastening thermofilter the cylinder head (see. Fig. Location of mounting the air tube and thermofilter turbocharger).
20. Remove the auxiliary V-belt.
The engine 1,8-I
21. Unscrew and remove the belt tensioner.
22. Remove the top casing of a gear belt, bolt for the crankshaft pulley a cranked shaft of the engine clockwise before combination of adjusting labels on pulleys with indexes. Wherein the first cylinder is located in the TDC in the compression stroke.
23. Release the tension roller, resulting in reduced tension of the toothed belt. Remove a gear belt from a camshaft pulley.
24. Using a paint or marker, mark the position of the crankshaft pulley with respect to the cylinder block and turn the crankshaft clockwise to any one piston is at the top dead center. Before installation of the toothed belt establish crankshaft in a position in which the first cylinder piston is at TDC in the compression stroke.
25. Unscrew the bolts and remove the cylinder head cover with gasket.
26. In the sequence shown in the figure, slowly and evenly loosen the bolts of the cylinder head.
27. Make sure that on the cylinder head and disconnect pipes, hoses and electrical connectors.
28. Remove the cylinder head from the engine and install it on two pieces of wood.
29. Remove the cylinder head gasket.




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Preparation for the installation of the head

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