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Volkswagen Workshop Service and Repair Manuals

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Specified torques > < Securing engine to assembly stand

Golf Mk5

Installing engine
Installing engine
Installation is carried out in the reverse order. When installing, note the following:
  Caution
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
t  To avoid damage to lines, ensure sufficient clearance to all moving or hot components.
–  Check clutch release bearing for wear and renew if necessary (vehicles with manual gearbox).
–  Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100 (vehicles with manual gearbox).
–  Check whether dowel sleeves for centring engine/gearbox have been fitted in cylinder block, insert if necessary.
   
–  Hook intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Align engine mountings as follows:
  N10-0160
t  There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side).
t  The side surface of the engine support -2- should be located parallel to the support arm -1-.
  A10-1661
t  Ensure that edges of support arm on gearbox assembly mounting -2- and gearbox console -1- are parallel on gearbox side.
–  Install pendulum support.
  Note
Specified torques for assembly mountings → Chapter.
Vehicles with manual gearbox
–  Install hydraulic clutch slave cylinder: → 6-speed manual gearbox 02S; Rep. gr.30.
–  Attach selector mechanism: → 6-speed manual gearbox 02S; Rep. gr.34.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
Vehicles with automatic gearbox
–  Installing selector lever cable → 7-speed dual clutch gearbox 0AM; Rep. gr.34.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
–  Install air conditioner compressor → Heating, air conditioning system; Rep. gr.87.
–  Install poly V-belt → Chapter.
–  Install catalytic converter and exhaust pipe.
Specified torques for exhaust system: → Chapter.
–  Electrical connections and routing: → Electrical system; Rep. gr.97.
–  Install engine splash protection.
–  Replenish coolant → Chapter.
–  Install air filter → Chapter.
–  Install battery and battery carrier → Electrical system; Rep. gr.27.
–  Connect battery → Electrical system; Rep. gr.27.
–  Connect → Vehicle diagnosis tester.
–  Erase learnt values and adapt engine control unit to throttle valve module → vehicle diagnosis tester„Guided functions“.
–  Carry out vehicle system test: → Vehicle diagnosis tester„Guided fault finding“.
–  Finish the vehicle system test so that any fault entries stored during assembly can be deleted automatically.
Observe applicable safety precautions during road test.
–  Carry out a road test.
–  Then carry out vehicle system test again and rectify any faults which may have occurred.
  A10-1662

Specified torques > < Securing engine to assembly stand