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Volkswagen Workshop Service and Repair Manuals

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Assembly mountings > < Removing engine (Polo)

Polo Mk5

Installing engine (Polo)
Installing engine (Polo)
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, coolant and refrigerant, 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-.
–  Bolt on gearbox.
Specified torques for gearbox: → Rep. gr.34
–  Rock engine to align engine mountings stress-free.
  Note
Specified torques for assembly mountings → Chapter
–  Install pendulum support.
–  Install drive shafts → Running gear, axles, steering; Rep. gr.40.
Vehicles with manual gearbox
–  Install slave cylinder of hydraulic clutch: → Rep. gr.30
–  Mount selector mechanism: → Rep. gr.34
Vehicles with dual clutch gearbox
–  Install selector lever cable: → Rep. gr.34
Continuation for all vehicles
–  Install air conditioner compressor → Heating, air conditioning system; Rep. gr.87.
–  Install poly V-belt → Chapter.
–  Electrical connections and routing: → Electrical system; Rep. gr.97.
–  Install noise insulation → General body repairs, exterior; Rep. gr.50.
–  Replenish coolant → Chapter.
–  Install air filter → Chapter.
–  Install battery and battery tray → Electrical system; Rep. gr.27.
–  Connect battery → Electrical system; Rep. gr.27.
–  Connect Vehicle diagnosis tester -VAS 5051-.
–  Erase learnt values and adapt engine control unit 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.
  N10-0160

Assembly mountings > < Removing engine (Polo)