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:
Driving with an automatic gearbox
First read and observe the introductory information
and safety warnings The gearbox changes the forward gears up and down automatically.
Driving down hills
The steeper the gradient, the lower the gear you will need. Lower gears increase
the braking effect of the engine. Never allow the vehic ...
Removing and installing rear underbody cover – petrol/diesel
Note
The removal and installation procedures may have to be modified
slightly depending on engine fitted.
–
Loosen lock washer -3-.
–
Unclip spreader rivet -2- and remove
bolt -4-.
–
Remove rea ...
Removing and installing onboard supply control unit -J519-, RHD vehicles
Note
When renewing the control unit, select
Renew function for the respective control unit in
Guided fault finding or
Guided functions mode
→ Vehicle
diagnostic tester.
Removing
â ...
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Securing engine on engine and gearbox support