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Volkswagen Workshop Service and Repair Manuals

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Specified torques > < Securing engine to assembly stand

Polo 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.
Vehicles with manual gearbox
–  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.
Vehicles with automatic gearbox
–  Only use nuts approved in parts programme to secure torque converter to drive plate.
Continuation for all vehicles
–  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-.
–  When swinging engine in, ensure that there is clearance between drive shafts.
–  Rock engine to align engine mountings stress-free.
  Note
Specified torques for assembly mountings → Chapter.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40
Vehicles with air conditioner
–  Install air conditioner compressor.
–  Install poly V-belt → Chapter.
Continuation for all vehicles
–  Electrical connections and routing: → Electrical system; Rep. gr.97
Vehicles with manual gearbox
–  Install hydraulic clutch slave cylinder → 5-speed manual gearbox 02T; Rep. gr.30
–  Install selector mechanism → 5-speed manual gearbox 02T; Rep. gr.34.
–  Install engine splash protection.
Vehicles with automatic gearbox
–  Reconnect selector lever cable to gearbox and adjust if necessary: → Automatic gearbox 001; Rep. gr.37
Continuation for all vehicles
–  Replenish coolant → Chapter.
–  Install air filter housing (engine codes AUA, AUB, BBY, BBZ, BKY) → Chapter.
–  Install air filter housing (engine codes BUD, CGGB) → Chapter.
–  Connect vehicle diagnostic, testing and information system -VAS 5051-.
–  Clear learnt values and adapt engine control unit to throttle valve module and exhaust gas recirculation valve -N18- → Vehicle diagnostic tester„Guided function“.
–  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.
–  The readiness code must be generated if the fault memory has been erased.
Observe applicable safety precautions during road test.
–  Carry out a road test.
–  Read control unit fault memory again.
  N10-0160

Specified torques > < Securing engine to assembly stand