volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

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Specified torques > < Removing

Polo Mk5

Installing
Installing
Installation is carried out in reverse order of removal. When installing, note the following:
–  Check clutch release bearing for wear and renew if necessary.
–  Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
–  Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary.
–  When swinging engine in, ensure that there is clearance between drive shafts.
–  Bolt gearbox flange to cylinder block.
Specified torque for gearbox: → 5-speed manual gearbox 02T; Rep. gr.34.
Specified torque for starter: → Electrical system; Rep. gr.27.
–  Rock engine to align engine mountings stress-free.
  Note
Specified torques for assembly mountings → Chapter.
Vehicles with air conditioner
–  Install air conditioner compressor → Heating, air conditioning system; Rep. gr.87.
Continuation for all vehicles
–  Electrical connections and routing: → Electrical system; Rep. gr.97
–  Install poly V-belt → Chapter.
–  Install thermostat housing. Specified torque for securing bolts: 10 Nm.
–  Install gearbox selector mechanism: → 5-speed manual gearbox 02T; Rep. gr.34.
–  Replenish coolant → Chapter.
–  Install air filter → Chapter.
–  Connect Vehicle diagnosis, testing and information system -VAS 5052-.
–  Erase learnt values and adapt engine control unit -J623- to throttle valve module → Vehicle diagnostic tester„Guided functions“.
–  Carry out vehicle system test → Vehicle diagnostic 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.
   

Specified torques > < Removing