Volkswagen Golf Service & Repair Manual: Installing engine
| 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.. |
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| – |
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. |
|
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| – |
First screw bolts -arrows- for
engine mountings into stop by hand. |
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| – |
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. |
| → Chapter „Assembly overview - assembly mountings“ |
| Securing gearbox to engine
→ Rep. gr.34 |
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Special tools and workshop equipment
required
Engine and gearbox support -VAS 6095-
...
Other materials:
Run-flat tyres, retrofitting/requirements when using run-flat tyres
Caution
Retrofitting run-flat tyres to vehicles may only be
undertaken if the tyres are fitted as standard or they
are available as an option.
These tyres may only be used ...
Electric windows – functions
First read and observe the introductory information
and safety warnings One-touch opening and closing
One-touch opening and closing makes it possible to fully open and close the windows.
The individual buttons do not have to be held down to do this.
For one-touch closing: pull the button fo ...
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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Securing engine on engine and gearbox support