Volkswagen Workshop Service and Repair Manuals

Installation is carried out in the reverse sequence, when doing this note the following:

• ‒ Lightly grease input shaft splines with G 000 100.
• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.

• ‒ When lowering the assembly, ensure that clearance exists between assembly and drive shafts.
• ‒ → When installing the engine mounting ensure that the recess on the rear console and the recess on the front console locates on the lugs of the bonded rubber mounting -arrows-.
• ‒ Align engine mountings stress-free by rocking.
• ‒ Installing P.A.S. vane pump:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes; Removing and installing power assisted steering vane pump

• ‒ Install ribbed belt .
• ‒ Install air conditioner compressor, vehicles with refrigerant R12:

=> Heating, air conditioning; Repair group 87; Refrigerant R12 air conditioning with manual control; Removing and installing compressor bracket - 4-cyl. petrol engine

• ‒ Install air conditioner compressor, vehicles with refrigerant R134a:

=> Heating, air conditioning; Repair group 87; Refrigerant R134a air conditioning with manual control; Removing and installing compressor bracket - 4-cyl. petrol engine

• ‒ Installing lock carrier with attachments:

=> General body repairs; Repair group 50; Body front; Servicing lock carrier with attachments

Engine codes ATU, AWF, AWG

• ‒ Installing lock carrier with attachments:

=> General body repairs, Convertible; Repair group 50; Body front; Servicing lock carrier with attachments

Continuation for all vehicles

• ‒ Install ribbed belt => Page 13-16 .
• ‒ Fill with coolant => Page 19-18

Vehicles with manual gearbox

• ‒ Install clutch cable:

=> 5-Speed manual gearbox 020; Repair group 30; Servicing clutch control; removing and installing clutch cable

• ‒ Adjust throttle cable => Page 20-10
• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Perform the work sequence "Procedure after interrupting voltage supply".

Engine codes AEK, AFT, AKS

• ‒ Carry out idling check:

=> Repair group 24; Simos injection and ignition system; idling check

=> Repair group 24; Motronic injection and ignition system; idling check

Engine codes ATU, AWF, AWG

=> Repair group 24; Engine control unit; Procedure after interrupting voltage supply.

• ‒ Read out readiness code:

=> Repair group 01; Readiness code; Reading out readiness code

• ‒ If the fault memory has been erased or the engine control unit separated from the permanent positive, the readiness code must be generated again.

=> Repair group 01; Readiness code; Generating readiness code

Continuation for all vehicles

• ‒ Carry out a test drive and interrogate fault memory:

=> Repair group 01; Self-diagnosis; Interrogating and erasing fault memory

• ‒ Check headlight adjustment and adjust if necessary:

=> Maintenance booklet