Volkswagen Workshop Service and Repair Manuals

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

Vehicles with manual gearbox

• ‒ Check clutch release bearing for wear, renew if necessary.
• ‒ Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.

Vehicles with automatic gearbox

• ‒ Only use nuts approved in parts programme to secure torque converter to drive plate.

Continuation for all vehicles

• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.
• ‒ When swinging the assembly in, ensure that clearance exists between the drive shafts.
• ‒ Align engine mountings stress-free by rocking.

• ‒ → When installing the engine mounting ensure that the pins on the bonded rubber mounting engage in the engine support bracket -arrows-.

Note:

Assembly mounting tightening torques

.

• ‒ Install drive shafts:

=> Running gear; Repair group 40; Removing and installing drive shafts

• ‒ Installing P.A.S. vane pump:

=> Running gear; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes

Vehicles with air conditioner

• ‒ Install air conditioner compressor.

Continuation for all vehicles

• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Install ribbed belt => Page 13-11 .

Vehicles with manual gearbox

• ‒ Installing clutch cable:

=> Repair group 30; Servicing hydraulic clutch control

• ‒ Connecting selector mechanism to gearbox.

=> Repair group 34; Servicing gear change mechanism

Vehicles with automatic gearbox

• ‒ Install selector cable on gearbox, adjust if necessary:

=> Repair group 37; Servicing selector mechanism; Dismantling and assembling selector mechanism

Continuation for all vehicles

• ‒ Adjust accelerator cable (vehicles with cable operated system) => Page 20-29
• ‒ Filling with coolant => Page 19-11
• ‒ Install air cleaner:

=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner.

• ‒ Match engine electronics control unit to throttle valve control part:

=> Repair group 24; Engine control unit; Matching engine control unit to throttle valve control part

Note:

On vehicles fitted with an automatic gearbox the gearbox control unit must also be adapted:

=> Self-diagnosis for automatic gearbox 001; Repair group 01; Performing self-diagnosis; Initiating basic setting