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:

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 ...

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