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Volkswagen Golf Workshop Service Manuals

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Aligning engine and gearbox mountings > < Securing engine to assembly stand

Installing the 4-cylinder injection engine on a Golf Mk4

Notes on installing
Notes on installing
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.
–  Check clutch release bearing for wear and renew if necessary.
–  Clean input shaft splines and lightly grease with G 000 100.
–  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.
–  Check centring of clutch drive plate, if necessary.
–  Align engine and gearbox mountings → Chapter.
–  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 drive shafts: → Running gear, axles, steering - front and four-wheel drive; Rep. gr.40.
–  Install starter catalytic converter → Chapter.
Vehicles with air conditioner
–  Install air conditioner compressor → Heating, air conditioning system; Rep. gr.87.
–  Install alternator: → Electrical system; Rep. gr.27.
Continuation for all vehicles
–  Install power steering vane pump: → Running gear, axles, steering - Front and four-wheel drive; Rep. gr.48
–  Install poly V-belt → Chapter.
–  Electrical connections and routing: → Electrical system; Rep. gr.97
–  Install upper part of intake manifold → Chapter.
–  Install air filter → Chapter.
–  Install centre, left and right noise insulation: → General body repairs, exterior; Rep. gr.50
–  Replenish coolant → Chapter.
–  Adapt engine control unit to throttle valve module and exhaust gas recirculation valve -N18- → Vehicle diagnostic, testing and information system VAS 5051.
–  Carry out road test and read fault memories → Chapter.
  N10-0160

Aligning engine and gearbox mountings > < Securing engine to assembly stand