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

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	Golf 4
		Instructions
		Engine
		Cooling system
		Fuel System
		Exhaust system
		Ventilation and heating system
		Coupling
		Transmission
			Removing and installing transmission
				Engines 1,8 / 1,9 / 2,3-I
				Engines 1,4 / 1,6-I
			Removing and installing automatic transmission
			The gear change mechanism
			Removal and installation of the case shift lever
			Adjust the shift cable
			Full automation
			Adjustment of draft of a cable shift lever
		Suspension brackets and power shafts
		Steering
		Wheels and tires
		Brakes
		Body
		Electrical equipment and wiring

printable version

Engines 1,8 / 1,9 / 2,3-I

Location and torque bolts transmission on models with engines 1,8 / 1,9

A, B - the location of the centering sleeves

1	M 12 x 55	80 Nm
2	M 12 x 150	80 Nm
3	M 10 x 50	40 Nm
4	M 7 x 12	10 Nm
5	M 7 x 12	10 Nm

Location and torque bolts transmission on models with engines 2,3-I

A, B - the location of the centering sleeves

1	M 12 x 55	80 Nm
2	M 12 x 55	80 Nm
3	M 12 x 65	80 Nm
4	M 12 x 70	40 Nm
5	M 10 x 60	10 Nm

Withdrawal

PERFORMANCE ORDER

1. 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.
2. Remove the air filter.
	3. Disconnect the electrical connectors from the tachometer sensor (1) and the reverse gear switch (2).
	4. Remove the stopper (A) and fastening the cable (B) of the gear lever. Unscrew the thrust gear selection with the lever (C) and turn it in the direction of the arrow.
	5. Release the spring clamp and remove the hose coupling from an arm on a transmission. Unscrew bolts and remove an arm of support transmission control cables from the gearbox.
6. Remove the two screws and remove the transmission clutch slave cylinder. Using a soft wire, suspend the clutch slave cylinder to the body, without disconnecting from it a hose. When removed, the clutch slave cylinder, do not press the clutch pedal.
	7. Remove the nut (1) and remove the tire from the ground power unit. Unscrew the holder (3) the starter and move it to the side. Unscrew the nut (2) on the starter.
8. Remove all the available top bolts transmission to the engine.
	9. Using a lifting device or a special tool VW 10-222A, lift the power unit so that the weight of the power unit was perceived by the load-lifting device.
10. Lift the car and remove the bottom mudguard of a motor compartment.
11. Remove the starter.
12. Remove the bracket from the power steering gear case.
	13. If you have to remove the protective cap of the right hinge flange (A) of the drive shaft. Remove the bolt (upper arrow) of fastening small partition behind the right drive shaft and remove the septum.
14. Remove the hinges of power shafts from a transmission. Using a soft wire, tie up drive shaft as high as possible to the body. It does not scratch the lacquer driveshafts.
15. Disconnect the exhaust system between the catalyst and middle silencer.
16. Remove the holders reception exhaust pipe from the gearbox. If necessary, remove a reception exhaust pipe.
	17. Remove the bolts securing the lower pendulum support of the power unit.
	18. Remove the screws (A), then the bolts (B) securing the left support of the power unit.
	19. Remove the support (A) from the transmission gearbox.
	20. At the bottom, set the special tool 457/1 (C) and fix its bolt M 8h25 (B) into the hole for fixing the pendulum support. Secure squeezing device 3300A (A) with two screws (indicated by arrows). Turn the screw squeezing device, move the transmission forward.
21. In the absence of special squeezing device, you can use a car jack.
	22. Support transmission with special grippers lift VW 3282. Alternatively you can support the transmission car jack through wooden bar.
23. Remove the bottom bolts of fastening of a transmission to the engine.
24. Move the transmission from the engine and lower it down. When lowering the gearbox do not damage the hoses of the power steering.

Setting

PERFORMANCE ORDER

1. When replacing the gearbox install a new gearbox taken from the old box speed sensor and the selector lever and gearshift.
2. Check the condition of the clutch.
3. Clean the splines of the drive shaft gearbox and grease with a thin layer of grease on the basis of molybdenum disulphide. Check that the clutch disc moves smoothly on the drive shaft of the gearbox.
4. Check that the engine block mounted guides for centering the gearbox.
	5. Move the lever of the clutch to the transmission housing and secure it in this position bolt M 8h35. After installing the transmission unscrew the bolt.
6. The horizontal move transmission to the engine, and the gearbox drive shaft must be logged in clutch disc. If the drive shaft is not included in the clutch disc splines for the drive shaft flange to rotate the shaft transmission to the appropriate position.
7. Supporting transmission arms, remove the device to support the transmission.
8. Screw the lower bolts of a transmission to the engine and the starter mounting bolts.
9. Remove the bolt M 8h35, the locking lever clutch in the transmission housing. The hole is then screwed into the bolt bracket shift cable.
10. Screw in and tighten the bolts from the hand of the left support of the power unit and the lifting mechanism move the power unit in the mounting position.
	11. Tighten the screws (A) securing the left support of the power unit to the body 25 Nm. Screw in new bolts (B) securing the left support of the power unit and tighten them by hand.
12. Screw the new pendulum support bolts and tighten them by hand.
13. Remove the lifting device, which supports the engine.
14. Move the power unit to the side, set it to the normal position on the supports of the power unit.
15. Tighten the support of the power unit to torque, then tighten them to 90 ?�.
16. Connect to a transmission drive shafts.
17. Install the large and small partition of the drive shaft.
18. Screw bolts pendular support of the power unit and tighten them to 50 Nm.
19. Install the starter.
20. Attach the shift cable and screw it to the box, tightening the bolts to 25 Nm.
21. Screw the bracket cable to the shift lever and tighten the bolt to 25 Nm.
22. Install the selector cable on the lever and secure it with a spring clip.
23. Adjust traction gear.
24. Tighten the focus shift lever and tighten the bolt to 25 Nm.
25. Connect the electrical connections to the gearbox.
26. Connect the wires to the starter.
	27. Lubricate the pusher clutch slave cylinder lubricant based on molybdenum disulfide. Install the clutch slave cylinder and fix its bolts, having tightened their moment of 20 Nm.
28. Repeatedly press the clutch pedal and check the operation of the clutch. If disconnects the clutch hydraulic circuit, remove it from the air.
29. Establish a reception exhaust pipe with catalytic converter with a new seal.
30. Install the screw to the crankcase and gearbox bracket power steering.
31. Check the condition of the oil in the gearbox.
32. Establish the bottom mudguard of a motor compartment.
33. Install the air filter housing.
34. Connect the ground cable to the battery.

Bolted connection	Engines 1,8- / 1,9- / 2,3-I
The drive to the holder	60 Nm + 90 ?�
Transmission to the holder	50 Nm + 90 ?�
Holder to the body	60 Nm + 90 ?�
Support to the gearbox	40 Nm + 90 ?�
Support to a body	20 Nm + 90 ?�

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Removing and installing transmission

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Engines 1,4 / 1,6-I