Volkswagen Workshop Service and Repair Manuals

Installation is carried out in the reverse sequence, when doing this note the 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 lowering the assembly, ensure that clearance exists between assembly and drive shafts.
• ‒ → When installing the engine mounting ensure that the rib on the rear right console also the recess on the front console locates on the lugs of the bonded rubber mounting -arrows-.
• ‒ Align engine mountings stress-free by rocking.
• ‒ Install lock carrier with attachments:

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

• ‒ Install hydraulic clutch slave cylinder:

=> 5-Speed manual gearbox 02A; Repair group 30; Servicing clutch release mechanism

• ‒ Installing P.A.S. vane pump:

Vehicles with air conditioner:

• ‒ Install air conditioner compressor:

=> Heating, air conditioner system; Repair group 87

• ‒ Fill with coolant
• ‒ Adjust throttle cable => Page 20-11
• ‒ Perform basic setting:

=> Digifant injection and ignition system (4-valve); Repair group 24; Digifant injection and ignition system; Performing basic setting

• ‒ Electrical connections and routing:

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

• ‒ Check headlight adjustment and adjust if necessary:

=> Maintenance

• ‒ If necessary adjust gearchange cables:

=> 5-Speed manual gearbox 02A; Repair group 34; Servicing selector mechanism; Adjusting selector mechanism

Vehicles 10.94 ▸

• ‒ Match engine electronics control unit to immobilizer:

=> Digifant injection and ignition system (4-valve); Repair group 24; Digifant injection and ignition system; Matching engine electronics control unit to immobilizer.