How to Pull and Dismantle VW Mk2 Golf 1.8L Block

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How to Pull and Dismantle VW Mk2 Golf 1.8L Block
93 Steps
Supplies
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1
Jack it up!

Jack it up!

2
Disconnect battery... Remove if desired.

Disconnect battery... Remove if desired.

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3
Unscrew oil pan bolt! - 19mm socket.

Unscrew oil pan bolt! - 19mm socket.

4
Drain the oil!

Drain the oil!

5
Disconnect airflow sensor

Disconnect airflow sensor

6
Pull vacuum line from intake manifold and...

Pull vacuum line from intake manifold and...

7
...from the pressure governor.

...from the pressure governor.

8
Leave connected to air cleaner!

Leave connected to air cleaner!

9
Disconnect idle air stabilizer sensor

Disconnect idle air stabilizer sensor

10
Loosen clamp on stabilizer hose to intake manifold

Loosen clamp on stabilizer hose to intake manifold

11
Leave hose connected to idle air stabilizer!

Leave hose connected to idle air stabilizer!

12
Loosen clamp on hose connected to throttle body.

Loosen clamp on hose connected to throttle body.

13
Pull hose from throttle body

Pull hose from throttle body

14
Lift air cleaner to expose lower exhaust hose

Lift air cleaner to expose lower exhaust hose

15
Loosen clamp on lower exhaust hose

Loosen clamp on lower exhaust hose

16
Remove air cleaner, vacuum lines and idle air stabilizer as a whole unit.

Remove air cleaner, vacuum lines and idle air stabilizer as a whole unit.

17
Loosen C-Clamp from lower radiator hose.

Loosen C-Clamp from lower radiator hose.

18
Pull hose to drain coolant from radiator

Pull hose to drain coolant from radiator

19
Remove pivot bolt from Alternator - #6 Allen Wrench

Remove pivot bolt from Alternator - #6 Allen Wrench

20
Remove sliding bolt from alternator - 13mm Socket

Remove sliding bolt from alternator - 13mm Socket

21
Pull the belt from the alternator pulley

Pull the belt from the alternator pulley

22
Pull the alternator off the mount and remove the wire clamps

Pull the alternator off the mount and remove the wire clamps

23
Note the position of the wires

Note the position of the wires

24
Remove small nut - 8mm Socket

Remove small nut - 8mm Socket

25
Pull the boot from the larger wire and remove large nut - 13mm Socket

Pull the boot from the larger wire and remove large nut - 13mm Socket

26
Note the position of the plug wires to the distributor

Note the position of the plug wires to the distributor

27
Pull plug 1...

Pull plug 1...

28
...plug 2...

...plug 2...

29
...plug 3...

...plug 3...

30
...and plug 4!

...and plug 4!

31
Remove the plug wires from the distributor cap

Remove the plug wires from the distributor cap

32
Time for the spark plugs... Plug 1! - Deep Welled Plug Socket

Time for the spark plugs... Plug 1! - Deep Welled Plug Socket

33
Plug 2!

Plug 2!

34
Plug 3!

Plug 3!

35
Plug 4!

Plug 4!

36
Disconnect Coolant Temperature Sensor

Disconnect Coolant Temperature Sensor

37
Loosen the top bolt mounting the coolant temperature sensor housing to cylinder head... - 10mm Socket

Loosen the top bolt mounting the coolant temperature sensor housing to cylinder head... - 10mm Socket

38
...Remove the bottom bolt... And then finish removing the top bolt (This helps to avoid cracking the housing).

...Remove the bottom bolt... And then finish removing the top bolt (This helps to avoid cracking the housing).

39
Loosen clamp connecting hose to the fuel pump...

Loosen clamp connecting hose to the fuel pump...

40
Pinch C-Clamp connecting top radiator hose to radiator...

Pinch C-Clamp connecting top radiator hose to radiator...

41
...and pull the hose!

...and pull the hose!

42
Carefully pull the hose from the fuel pump (the dip stick makes this difficult).

Carefully pull the hose from the fuel pump (the dip stick makes this difficult).

43
Take the hoses out as a whole unit

Take the hoses out as a whole unit

44
Loosen clamp on hose connecting head cover and intake manifold

Loosen clamp on hose connecting head cover and intake manifold

45
Pull directly up on the oil screen from the head cover

Pull directly up on the oil screen from the head cover

46
Off it goes!

Off it goes!

47
Remove bolt fastening bracket to head cover -  10mm socket

Remove bolt fastening bracket to head cover - 10mm socket

48
Now for the head cover bolts... All 8 of 'em! Bolt 1! - 10mm Socket

Now for the head cover bolts... All 8 of 'em! Bolt 1! - 10mm Socket

49
Bolt 2!

Bolt 2!

50
Bolt 3!

Bolt 3!

51
Bolt 4!

Bolt 4!

52
Bolt 5!

Bolt 5!

53
Bolt 6!

Bolt 6!

54
Bolt 7!

Bolt 7!

55
Bolt 8!

Bolt 8!

56
Once the bolts are removed, the reinforcement strips are free. Set them aside.

Once the bolts are removed, the reinforcement strips are free. Set them aside.

57
Tilt the head cover back and lift it out at an angle (may need to shimmy it out if pinched by the intake)

Tilt the head cover back and lift it out at an angle (may need to shimmy it out if pinched by the intake)

58
Now we're down to the cam shaft cover!

Now we're down to the cam shaft cover!

59
Loosen the belt tensioner - 14mm Socket

Loosen the belt tensioner - 14mm Socket

60
Pull the belt tensioner out...

Pull the belt tensioner out...

61
While sliding the belt off the camshaft pulley

While sliding the belt off the camshaft pulley

62
Once freed, rest the belt on the lower pulleys

Once freed, rest the belt on the lower pulleys

63
Loosen the clamp on the BLUE fuel return line

Loosen the clamp on the BLUE fuel return line

64
Pull the fuel return line from the fuel pressure regulator

Pull the fuel return line from the fuel pressure regulator

65
Loosen the C-Clamp on the BLACK fuel supply line.

Loosen the C-Clamp on the BLACK fuel supply line.

66
Pull the fuel supply line from the fuel rail.

Pull the fuel supply line from the fuel rail.

67
Unscrew the Phillips screws mounting the fuel pressure regulator... Top here...

Unscrew the Phillips screws mounting the fuel pressure regulator... Top here...

68
...bottom here.

...bottom here.

69
Loosen and remove Socket head mounting bolt. - 6mm hex wrench

Loosen and remove Socket head mounting bolt. - 6mm hex wrench

70
Pull the fuel pressure regulator from the mounting bracket/fuel rail

Pull the fuel pressure regulator from the mounting bracket/fuel rail

71
Keep the bracket and pressure regulator together

Keep the bracket and pressure regulator together

72
Remove the socket head mounting bolt securing the fuel rail to the intake manifold.... Left here... - 5mm hex wrench

Remove the socket head mounting bolt securing the fuel rail to the intake manifold.... Left here... - 5mm hex wrench

73
...right here.

...right here.

74
Disconnect fuel injector wire harness

Disconnect fuel injector wire harness

75
Pull the fuel rail (with injectors) from the head. This will require some shimmying and a good amount off effort.

Pull the fuel rail (with injectors) from the head. This will require some shimmying and a good amount off effort.

76

To be continued...

77
See that exhaust hose?

See that exhaust hose?

78
Loosen the clamp from the exhaust manifold... And remove the hose!

Loosen the clamp from the exhaust manifold... And remove the hose!

79
Time for the head bolts!!! - 12-point (13mm) star bit

Time for the head bolts!!! - 12-point (13mm) star bit

80
With a Torque wrench, loosen head bolts starting from outside bolts to the center bolts.

With a Torque wrench, loosen head bolts starting from outside bolts to the center bolts.

81
82
With a monkey wrench, loosen "---" sensor.

With a monkey wrench, loosen "---" sensor.

83
And remove it!

And remove it!

84
85
Remove intake manifold mounting bolts - 6mm hex wrench

Remove intake manifold mounting bolts - 6mm hex wrench

86
Loosen bolt grounding wires to intake manifold. - 10mm socket

Loosen bolt grounding wires to intake manifold. - 10mm socket

87
Loosen screw clamp of "---" hose to intake.

Loosen screw clamp of "---" hose to intake.

88
Disconnect sensor behind intake manifold

Disconnect sensor behind intake manifold

89
Pull C-Clamp mounting the throttle cable to the intake manifold.

Pull C-Clamp mounting the throttle cable to the intake manifold.

90
And it's off!

And it's off!

91
Pull the throttle cable off!

Pull the throttle cable off!

92
Pry off the securing clip from the end of the throttle cable.

Pry off the securing clip from the end of the throttle cable.

93
Remove bolt securing "---" line. - 10mm socket

Remove bolt securing "---" line. - 10mm socket

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