VW Golf manuals

Volkswagen Golf Service & Repair Manual: Installing engine

Procedure
Engine/gearbox assembly secured to engine support T10497.
  Note
Renew bolts that are tightened with specified tightening angle.
Renew self-locking nuts and bolts as well as gaskets, seals and O-rings.
Secure all hose connections with the same types of hose clips as original equipment → Electronic Parts Catalogue.
Reinstall all cable ties in the same locations when installing.
–  Install intermediate plate → Fig..
   
–  If there are no dowel sleeves -A- in cylinder block for centring engine and gearbox, insert new ones.
–  Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
–  Install gearbox support.
–  Take up engine/gearbox assembly with engine support T10497.
–  Guide engine/gearbox assembly into body.
 

Installing engine

–  First screw bolts -arrows- for engine mountings into stop by hand.
 

Installing engine

–  First screw bolts -arrows- for gearbox mountings into stop by hand.
  Note
The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter.
–  Detach engine support T10497 from engine.
–  Install starter → Electrical system; Rep. gr.27.
–  Install air pipe → Chapter.
–  Installing air ducts → Fig..
Vehicles with manual gearbox
–  Install clutch slave cylinder → Rep. gr.30.
–  Install cables with cable support bracket → Rep. gr.34.
Vehicles with dual clutch gearbox
–  Install selector lever cable, fit connector of mechatronic and install all retainers on gearbox: → Rep. gr.34
Continuation for all vehicles
–  Install catalytic converter → Chapter.
Vehicles with four-wheel drive
–  Install flexible coupling of propshaft to bevel box → Final drive, differential; Rep. gr.39.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
–  Install transverse link, swivel joint and coupling rod → Running gear, axles, steering; Rep. gr.40.
–  Install air conditioner compressor → Heating, air conditioning; Rep. gr.87.
–  Install poly V-belt → Chapter.
–  Electrical connections and routing → Electrical system; Rep. gr.97 and → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Install engine control unit -J623- → Chapter.
–  Connect coolant hoses with plug-in connector → Fig..
–  Install pendulum support → Chapter.
–  Install left and right front wheel housing liner → General body repairs, exterior; Rep. gr.66.
–  Install front wheels → Running gear, axles, steering; Rep. gr.44.
–  Adjust assembly mountings → Chapter.
–  Install battery tray → Electrical system; Rep. gr.27.
–  Install air filter housing → Chapter.
  Note
Never use battery charging equipment for boost starting.
Danger of destroying control units through excessive voltage.
–  Replenish coolant → Anchor.
  Note
Do not reuse coolant which has been drained off.
Specified torques
→ Chapter „Assembly overview - assembly mountings“
Securing gearbox to engine → Rep. gr.34
 

Installing engine

Securing engine on engine and gearbox support
Special tools and workshop equipment required     Engine and gearbox support -VAS 6095- ...

Assembly mountings
...

Other materials:

Relay carrier, fuse carrier in dash panel/A-pillar, LHD vehicles
1 -  Bracket For parking aid control unit -J446-/park assist steering control unit -J791- Removing and installing → Chapter 2 -  Bracket For onboard supply control unit -J519- ...

Fuse table
Fig. 230 In the dash panel: fuse layout First read and observe the introductory information and safety warningsThe table shows the fuse locations for the items of electrical equipment which are most relevant to the customer. The left column contains the location, the other columns contain t ...

O-ring
These O-rings seal the joints between the individual components of the refrigerant circuit. Use only seals that are resistant to refrigerant R134a and its associated refrigerant oils. This is assured by using genuine replacement parts. ...

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