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:

Assembly overview - rear wheel housing liner
  Note   Minor differences may be encountered in respect of front wheel housing liner, depending on vehicle model.   Only the left side is shown. The right side is similar. 1 -  Rear wheel housing liner Materi ...

Expansion valve
The expansion valve atomises incoming refrigerant and regulates the flow so that, depending on the heat transport, the vapour does not become a gas until it reaches the outlet of the evaporator.   ...

Introduction
This chapter contains information on the following subjects:  → Indicator lamp    → Windscreen wiper lever    → Windscreen wiper functions    → Service position for the front windscreen wipers    → Rain sensor    → Checking and refilling t ...

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