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:

Vibration, vibration control system
Using the vibration control system -VAS 6230 A- you can perform more functions than just stationary balancing. A special feature of this system is the testing of the radial force of the wheel and tyre while rolling. A ro ...

Removing and installing metering pump -V54-, Golf and Golf Estate
  Note Pay attention to correct part number of metering pump -V54- (different versions) → Electronic Parts Catalogue. Removing   Note Observe safety precautions for working on f ...

Removing and installing lower seat pan frame with seat longitudinal adjustment motor -V28-/-V31-
Removing –  If possible, move front seat to highest position to reduce as much tension on torsion rod as possible. –  Remove front seat → Chapter. –  ...

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