volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Specified torques > < Notes on removing
Notes on installing
Notes on installing
Installation is carried out in the reverse order, note the following:
Version with clutch cable:
–  Lightly grease input shaft splines with grease for clutch plate splines -G 000 100-.
Version with hydraulic clutch:
–  Check clutch release bearing for wear and renew if necessary.
–  Lightly lubricate clutch release bearing, release bearing guide sleeve and splines on input shaft with grease for clutch plate splines -G 000 100-.
All versions:
–  Check whether dowel sleeves for centring engine/gearbox have been fitted in cylinder block, insert if necessary.
–  When lowering assembly, ensure that there is clearance between drive shafts.
   
–  When installing engine mounting ensure that the cut-outs in rear right console and front console engage in bonded rubber bush pins -arrows-.
–  Rock engine to align engine mountings stress-free.
Version with clutch cable:
–  Install clutch cable → 5-speed manual gearbox 020; Rep. Gr.30.
Version with hydraulic clutch:
–  Install hydraulic clutch slave cylinder → 5-speed manual gearbox 02C; Rep. Gr.30.
All versions:
–  Install power steering vane pump → Running gear; Rep. Gr.48.
–  Install air conditioner compressor → Heating, air conditioning; Rep. Gr.87.
–  Install lock carrier with add-on parts → General body repairs, exterior; Rep. Gr.50.
Engines with poly V-belt drive without tensioning roller:
–  Install poly V-belt → Anchor.
–  Fill with coolant → Chapter.
–  Adjusting throttle cable → Chapter.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Check ignition timing, adjust if necessary → Engine, mixture preparation; Rep. Gr.28
–  Perform idling check → Engine mixture preparation; Rep. Gr.24.
–  Check headlight adjustment and correct if necessary → Lights, bulbs, switches - exterior; Rep. Gr.94
–  If necessary adjust selector cables → 5-speed manual gearbox 02C; Rep. Gr.34
  V10-1456

Specified torques > < Notes on removing