Volkswagen Golf/Jetta/Cabriole 1990-1999

Engine

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If the engine must be removed in order to service it, there are a few preliminary steps which must be executed first.



Clear a place to work.
 
Clean the engine compartment as well as the engine. This will help keep both you and your tools cleaner.
 
Assume the vehicle will be out of order for quite some time.
 
Label all hoses, wires, components, etc.
 
Always plan ahead. Estimate the amount of needed time, tools, etc. Don't get cut short. This is a lengthy task.
 

Removal & Installation



The engine and transmission are removed as a unit and then disassembled. The removal of some front body work may be required.

Gasoline Engines
4 cyl.

NOTE
It is recommended that the hood be removed, to allow easier access to all areas of the engine, although it is not required.

Always label all lines and hoses so they can be reconnected correctly.


NOTE
On the 8 valve engines, special tools are required to remove and install the exhaust pipe to manifold spring clamps. These may be available at local parts retailers.


CAUTION
Fuel lines may be pressurized. Make sure the work area is well ventilated. Vapors can easily ignite.

  1. Disconnect the battery cables and remove the battery.
  2.  
  3. If your vehicle is equipped with an anti-theft system, know your deactivation code before you remove any of the battery cables.
  4.  
  5. Relieve the fuel system pressure by completing the following:

    Remove the fuel filler cap to relieve tank pressure.
     
    Loosen the cold start injector line to relieve the fuel system pressure on CIS-E fuel injection systems.
     
    On Digifant fuel injection, loosen the pressure test port fitting at the end of the fuel rail that supplies the injectors.
     

  6.  
  7. The air intake duct between the air cleaner and the throttle body must also be removed.
  8.  
  9. Detach the accelerator cable from the throttle and remove the cable housing from the bracket.
  10.  
  11. Set the heater temperature control to maximum.
  12.  
  13. Remove the radiator cap and place a pan under the thermostat housing and remove the thermostat flange to drain the coolant.
  14.  
  15. Remove the air conditioner compressor and the condenser without disconnecting the coolant lines and secure them out of the way.
  16.  
  17. Remove the upper radiator hose and disconnect the wiring from the radiator fan motor and switches. Remove the upper mounting brackets and lift out the radiator and fan as an assembly.
  18.  
  19. On Golf and Jetta, the front body section must be removed:

    Detach the headlight electrical connectors and the hood release cable from the hood latch assembly.
     
    Remove the lower valance and the front grille, and front apron.
     

  20.  
  21. Disconnect all electrical connections and vacuum lines, carefully labeling each one.
  22.  


NOTE
Don't forget ground connections that are screwed to the body.

  1. Remove the power steering pump and reservoir.
  2.  


NOTE
You may not have to disconnect the hydraulic lines and secure them out of the way.

  1. The entire fuel injection system can be removed as a unit if the vehicle is equipped with the CIS-E type.

    Without disconnecting the lines, carefully pry the injectors from their holes and protect them with caps.
     

  2.  


NOTE
A little silicone spray can greatly ease the removal of the injectors.



As you remove the cold start injector, tape all the injector lines together and set them aside.
 
Detach the wiring and the fuel supply line from the fuel distributor. Plug the fuel inlet to keep dirt out of the fuel distributor.
 
Disconnect the fuel return line from the pressure regulator.
 
Remove the bolts or clips required to change the air filter and lift the air flow sensor and fuel system out of the vehicle.
 

  1. On engines with Digifant fuel injection, disconnect the fuel supply line from the pressure regulator and the fuel return line from the fuel rail. Disconnect the plug on the end of the injector wiring harness.
  2.  
  3. If equipped with an automatic transaxle, place the selector lever in the "PARK" position and disconnect the shifter cable at the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
  4.  
  5. On vehicles with a manual transaxle, remove the 2 rods with the plastic socket ends and unbolt the remaining linkage from the transaxle case as required. Disconnect the clutch cable, lift it from the case and set it aside.
  6.  
  7. Detach the wiring from the starter and the back-up light switch and disconnect the ground cable from the transaxle. Remove the speedometer cable from the transaxle and plug the hole in the case.
  8.  
  9. Raise and safely support the vehicle on jack stands.
  10.  
  11. Unbolt the halfshafts from the flanges and hang them from the body with wire.
  12.  


WARNING
DO NOT let the halfshafts hang by the outer CV joint or the joint may fall apart.

  1. Unbolt the exhaust pipe from the manifold or remove the spring clamps holding the exhaust pipe to the manifold and lower the pipe.
  2.  
  3. If the exhaust pipe is secured to the manifold with spring clamps, use the proper tools and procedures for removal and installation.
  4.  


CAUTION
The springs are under heavy tension and can cause serious injury if mishandled.

  1. To remove the spring clamps:

    Push the pipe to one side to expand the opposite clamp. Insert a wedge into the expanded clamp.
     
    Push the pipe to the other side and insert a wedge into the clamp.
     
    Push the pipe the other way again to expand the clamp further. It should be possible to grab the wedge with locking pliers and pry the clamp off the pipe flange.
     
    Leave the wedges in the clamps and put them in a box so they won't be disturbed and fly apart.
     

  2.  
  3. Attach a suitable chain sling to the lifting eyes.
  4.  


NOTE
On 16V engines, a rigid sling must be used. Remove the idle stabilizer valve and upper intake manifold and attach engine sling tool VW-2024A or equivalent, to the engine.

  1. Check to make sure everything is disconnected, then unbolt the mounts. Remove the starter first and the front mount with it.
  2.  
  3. Once all of the mounts have been unbolted, slightly lower the engine/transaxle assembly and tilt it towards the transaxle side.
  4.  
  5. Next, carefully lift the assembly from the vehicle. See for information on separating the engine and transaxle.
  6.  

To install:


NOTE
See for information on assembling the engine and transaxle. Make sure all mount brackets are securely bolted to the engine/transaxle. Fit the assembly into the engine bay and install the mounts, starting at the rear. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.

  1. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at the rear and working forward. Torque to 33 ft. lbs. (41 Nm) for 10mm bolts or 54 ft. lbs. (73 Nm) for 12mm bolts.
  2.  
  3. Install the starter and torque the bolts to 33 ft. lbs. (45 Nm).
  4.  
  5. Attach the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Connect the exhaust pipe. On 16V engines, use new self locking nuts to secure the flange and torque the nuts to 30 ft. lbs. (40 Nm).
  8.  
  9. Attach the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  10.  
  11. Install the fuel system components and connect the lines.
  12.  
  13. On Golf and Jetta, install the front apron and connect the wiring.
  14.  
  15. Install the air conditioning compressor and/or power steering pump, if equipped. Install and adjust the drive belts.
  16.  
  17. Install the radiator, fan and heater hoses.
  18.  
  19. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  20.  
  21. Connect all remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  22.  
  23. Fill the cooling system. Check the adjustment of the accelerator cable.
  24.  

VR-6


Click image to see an enlarged view

Fig. The use of a narrow 15°V-6 allows VW to fit a more powerful engine (such as this VR6) where others cannot


NOTE
The factory audio system is coded. Know your code before you remove the battery cables.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the engine accessory drive belt.
  6.  


NOTE
General practice is to mark the accessory drive belt's rotation before removing the belt. This will aid in the installation of the belt.

  1. Remove the spark plug connectors from the plugs, then remove the plug wire guides.
  2.  


NOTE
A special tool is required to remove the spark plug connectors from the plugs. A version of this tool is connected to the front hood support bar.

  1. Remove the round harness connector near the ignition coil on the rear of the cylinder head.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Label and then disconnect all wires, hoses, and clips attached to the cylinder head.
  6.  
  7. Remove the air filter housing and intake air ducts. This only applies to vehicles with mass air flow sensors.
  8.  
  9. Disconnect the accelerator cable from the throttle.
  10.  
  11. Label then disconnect the fuel hoses from the cylinder head and position them out of the way.
  12.  
  13. Remove all necessary coolant hoses.
  14.  
  15. Detach the exhaust pipes from the manifolds.
  16.  
  17. Remove the drive axles.
  18.  
  19. Remove the radiator mounting bolts.
  20.  
  21. If the vehicle has A/C, remove all necessary components. This will require the skills of a certified technician to evacuate the refrigerant from the system.
  22.  
  23. Detach the front body mounting bolts.
  24.  
  25. Remove all remaining electrical connectors, hoses, and brackets from the radiator assembly.
  26.  
  27. On vehicles with A/C, remove the radiator and the A/C condenser as a unit.
  28.  
  29. Unbolt and remove the power steering pump from its bracket and set it to the side.
  30.  
  31. Remove the electrical harness connectors from the transmission-automatic transmission equipped vehicles.
  32.  
  33. Detach the transmission cooler lines from the transmission-automatic transmission equipped vehicles.
  34.  
  35. Remove the clutch slave cylinder on manual transmission vehicles.
  36.  
  37. On automatic transmission equipped vehicles, place the selector lever in the park position.
  38.  
  39. Label the starter wiring from the starter. Then remove the wiring from the alternator.
  40.  
  41. Remove the intake air temperature sensor (IAT).
  42.  
  43. Install the engine hoist.
  44.  



Click image to see an enlarged view

Fig. Installation of an engine hoist

  1. Remove the motor mounts.
  2.  



Click image to see an enlarged view

Fig. Remove the motor mounts

  1. Raise the engine and transmission from the vehicle.
  2.  

To install:


NOTE
See for information on assembling the engine and transaxle. Make sure all mount brackets are securely bolted to the engine/transaxle. Fit the assembly into the engine bay and install the mounts, starting at the rear. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.

  1. Properly torque all motor mount nuts and bolts. See included art for torque specs.
  2.  



Click image to see an enlarged view

Fig. Engine/transaxle mount-front



Click image to see an enlarged view

Fig. Engine/transaxle mount-right rear



Click image to see an enlarged view

Fig. Engine/transaxle mount-left rear

  1. Using the engine hoist, lower the engine into the bay.
  2.  
  3. Install the front body assembly
  4.  
  5. Install all removed components, connectors, hoses, lines, etc.
  6.  
  7. The remainder of the installation process is the reverse of removal.
  8.  


NOTE
Tighten the drive axle flange bolts to 33 ft. lbs. (45 Nm) and the exhaust pipe to exhaust manifold to 30 ft. lbs. (40 Nm).

Fox

The engine is lifted from this vehicle without the transaxle attached.

  1. Disconnect the battery ground cable and remove the battery.
  2.  
  3. Open the heater valve and the cap on the coolant expansion tank. Drain the coolant by removing the bottom hose. Disconnect the electrical connector from the radiator cooling fan.
  4.  
  5. Remove the radiator and fan as an assembly.
  6.  
  7. If equipped with air conditioning, remove the compressor and condenser and place them aside without disconnecting any refrigerant lines.
  8.  
  9. Detach and label all the electrical wires and vacuum lines connecting the engine to the body.
  10.  
  11. Much of the fuel system can be removed as a unit without disconnecting fuel lines. Remove the injectors from their holes and protect them with caps. Remove the cold start injector and warm-up regulator, if equipped. Disconnect the throttle cable and remove the air duct. Place these aside without disconnecting the fuel lines.
  12.  
  13. Disconnect the speedometer cable from the transaxle and plug the hole. Detach the clutch cable.
  14.  
  15. Loosen the charcoal filter clamp and move the filter to the rear of the engine compartment.
  16.  
  17. Remove the upper engine-to-transaxle bolts.
  18.  
  19. Remove the left and right engine mounting nuts.
  20.  
  21. Remove the front engine stop and the starter.
  22.  
  23. Remove the clutch cover and the 2 lower engine-to-transaxle bolts.
  24.  
  25. Disconnect the exhaust pipe from the manifold at the flange. Then remove the bolt from the exhaust pipe support and remove the exhaust pipe from the manifold.
  26.  
  27. Install transaxle support bar VW-758/1 or equivalent, with slight preload. This is to hold the transaxle in place while the engine is out.
  28.  
  29. Install sling US-1105, or equivalent, on the engine lifting eyes located on the left side of the cylinder head.
  30.  
  31. Lift the engine until its weight is taken off the engine mounts.
  32.  
  33. Adjust the support bar to contact the transaxle.
  34.  
  35. Separate the engine and transaxle.
  36.  
  37. Carefully lift the engine out of the engine compartment so as not to damage the transaxle main shaft, clutch and body.
  38.  

To install:

  1. Lubricate the clutch release bearing and transaxle main shaft splines with MOS 2 grease or equivalent; do not lubricate the guide sleeve or the clutch release bearing.
  2.  
  3. Carefully guide the engine into the vehicle and attach to the transaxle while keeping weight off the motor mounts.
  4.  
  5. Remove the transaxle support bar and lower the engine onto the engine mounts.
  6.  
  7. The remainder of the installation is the reverse of the removal procedure. Torque the engine mounts and subframe bolts with the engine running at idle speed. This will minimize vibration.
  8.  
  9. Torque the following:

    Cold start valve, the radiator mount bolts and the engine-to-transaxle cover plate bolts-7 ft. lbs. (10 Nm).
     
    Engine-to-transaxle bolts-42 ft. lbs. (55 Nm).
     
    Engine mount bolts-30 ft. lbs. (40 Nm).
     
    Engine stop-to-body block and exhaust pipe support bolts-18 ft. lbs. (25 Nm).
     
    Exhaust pipe-to-manifold bolts-22 ft. lbs. (30 Nm).
     
    Starter bolts-18 ft. lbs. (25 Nm).
     

  10.  

Diesel Engine

The engine and transmission are lifted from the vehicle as an assembly and separated afterwards. Some of the front body work must be removed but removing the hood is not necessary unless it interferes with the lifting equipment. Some components can be removed without disconnecting hydraulic or coolant hoses. Cover the front fenders so components can be hung over them. Before beginning the job, make sure you have some way of labeling the wires, lines and hoses so they can be reconnected correctly.

  1. Remove the battery.
  2.  
  3. Turn the heater temperature control to maximum. Remove the radiator cap and the radiator hose at the thermostat housing and drain the cooling system. Remove the thermostat flange.
  4.  
  5. Disconnect the wiring from the radiator fan motor and the thermo-switch. Remove the upper radiator mounting brackets and lift the radiator and fan out of the vehicle.
  6.  
  7. Remove the fuel filter and base. Cap the fuel line connections to prevent leakage.
  8.  
  9. Detach the brake booster hose from the vacuum pump.
  10.  
  11. Remove the alternator wiring and then the unit.
  12.  
  13. Detach the wiring to the fuel shut-off solenoid, the glow plugs, the oil pressure switch and the coolant temperature sensor.
  14.  
  15. Disconnect the heater and the expansion tank hoses.
  16.  
  17. At the injection pump, disconnect the accelerator cable and the cold start cable.
  18.  
  19. Disconnect the fuel supply and the return lines from the injection pump. Plug the openings in the pump and cap the ends of the lines to prevent the entry of dirt into the system.
  20.  
  21. If equipped with air conditioning, the injection pump must be removed to remove the compressor. See for instructions on removing the pump. To remove the compressor:

    Remove the air conditioning belt tensioner, water pump pulley and drive belt.
     
    Disconnect the wiring from the compressor and the pressure switches.
     
    Remove the condenser and compressor together without disconnecting the coolant hoses.
     
    Secure the compressor and condenser out of the way. Do not let them hang by the coolant hoses.
     

  22.  
  23. Remove the front body section as described:

    Disconnect the headlight electrical connectors and the hood release cable from the hood latch assembly.
     
    Remove the lower valance and the front grille.
     
    Remove the front apron
     

  24.  
  25. If equipped with power steering, remove the pump without disconnecting the hydraulic hoses. Secure the pump out of the way, do not let it hang by the hoses.
  26.  
  27. Disconnect the wiring from the starter, back-up light switch and the transaxle mount ground wire.
  28.  
  29. If equipped with a manual transaxle, disconnect the clutch cable and shift linkage.
  30.  
  31. On vehicles with an automatic transaxle, place the selector lever in the P position and disconnect the shifter cable at the transaxle.
  32.  
  33. Remove the speedometer cable from the transaxle and plug the hole in the case.
  34.  
  35. If not already done, raise and safely support the vehicle on jack stands.
  36.  
  37. Unbolt the halfshafts from the flanges and hang them from the body with wire.
  38.  


WARNING
DO NOT let the halfshafts hang by the outer CV joint or the joint may fall apart.


NOTE
The exhaust pipe is secured to the manifold with spring clamps. Use the proper tools and procedures for removal and installation. The springs are under heavy tension and can cause serious injury if mishandled.

  1. To remove the exhaust pipe spring clamps:

    Push the pipe to one side to expand the opposite clamp. Insert a wedge into the expanded clamp.
     
    Push the pipe to the other side and insert a wedge into the clamp.
     
    Push the pipe the other way again to expand the clamp further. It should be possible to grab the wedge with locking pliers and pry the clamp off the pipe flange.
     

  2.  
  3. Leave the wedges in the clamps and put them in a box so they won't be disturbed and fly apart.
  4.  
  5. Check carefully to make sure all necessary wiring, hoses and linkages have been disconnected. Attach a chain yoke and a hoist to the engine, then lift it slightly.
  6.  
  7. Unbolt the engine mounts, tilt the assembly down at the transaxle side and carefully lift the engine and transaxle out. See for information on separating the engine and transaxle.
  8.  

To install:


NOTE
See for information on assembling the engine and transaxle. Make sure all mount brackets are securely bolted to the engine/transaxle. Fit the assembly into the engine bay and install the mounts, starting at the rear. Start all nuts and bolts that secure the mounts to the body but don't tighten them yet.

  1. With all mounts installed and the engine safely in the vehicle, allow some slack in the lifting equipment. With the vehicle safely supported, shake the engine/transaxle as a unit to settle it in the mounts. Torque all mounting bolts, starting at the rear and working forward. Torque to 33 ft. lbs. (41 Nm) for 10mm bolts or 54 ft. lbs. (73 Nm) for 12mm bolts.
  2.  
  3. Install the starter and torque the bolts to 33 ft. lbs. (45 Nm).
  4.  
  5. Connect the halfshafts to the flanges and torque the bolts to 33 ft. lbs. (45 Nm).
  6.  
  7. Connect the exhaust pipe.
  8.  
  9. Connect the shift linkage and the clutch cable. Adjust the clutch and shift linkage as required.
  10.  
  11. Install the front apron and connect the wiring.
  12.  
  13. Install the air conditioner compressor and condenser.
  14.  
  15. Install the fuel injection pump as described in .
  16.  
  17. Install the power steering pump. Install and adjust all accessory drive belts.
  18.  
  19. Install the radiator, fan and heater hoses. Use a new O-ring on the thermostat and torque the thermostat housing bolts to 7 ft. lbs. (10 Nm).
  20.  
  21. Install the remaining components and connect all remaining wiring and vacuum hoses. Check carefully to make sure all components are correctly installed and connected.
  22.  
  23. Fill and bleed the cooling system. Check the adjustment of the accelerator cable.
  24.  

 
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