Volkswagen Workshop Service and Repair Manuals

Installing is basically in the reverse order but note following:

• ‒ 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.
• ‒ 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, if necessary loosen engine mountings to body.

• ‒ → When installing the engine mounting ensure that the bonded rubber bush pins locate in the engine mounting -arrows-.
• ‒ Renew pointed bolt for securing shift finger (clean threads in shift finger).
• ‒ Installing P.A.S. vane pump:

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

• ‒ Install clutch cable:

=> 5-Speed manual gearbox 085; Repair group 30; Servicing clutch mechanism; Removing and installing clutch cable.

• ‒ Install lock carrier with attachments:

=> General body repairs; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

Vehicles with air conditioner:

• ‒ Install air conditioner compressor:

=> Heating, air conditioner system; Repair group 87

• ‒ Electrical connections and routing:

=> Current flow diagrams, Electrical fault finding and Fitting locations

• ‒ Secure all pipes and hoses with cable ties and clips again. When doing this note coloured markings.
• ‒ Fill with coolant
• ‒ Adjust throttle cable => Page 20-22
• ‒ Check and if necessary adjust ignition timing:

=> Repair group 28; Injection and ignition system; Checking and adjusting ignition timing.

• ‒ Perform basic setting:

=> Repair group 24; Injection and ignition system; Performing basic setting

• ‒ Match engine electronics control unit to immobilizer:

=> Repair group 24; Injection and ignition system; Matching engine electronics control unit to immobilizer.