Volkswagen Workshop Service and Repair Manuals

Installation is carried out in the reverse sequence, when doing this note the following:

• ‒ Insert in the cylinder block new dowel sleeves for centralising engine and gearbox.
• ‒ → Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.

Models with a manual gearbox

• ‒ Lightly grease input shaft splines with G 000 100 grease.
• ‒ Check clutch and clutch operating mechanism, then install.

=> 5-speed manual gearbox 02J; Repair group 30; Servicing clutch control

• ‒ Install gear shift mechanism, adjust gear shift cables if necessary:

=> 5-speed manual gearbox 02J; Repair group 34; Servicing selector mechanism

Vehicles with automatic gearbox

• ‒ Install selector cable on gearbox, adjust if necessary:

=> Automatic gearbox 01M; Repair group 37; Servicing selector mechanism; Removing and installing cable

Vehicles with air conditioning

• ‒ Install air conditioner compressor:

=> Heating, air conditioning; Repair group 87; Removing and installing the compressor bracket

Continuation for all models

• ‒ When installing the engine/gearbox assembly, ensure sufficient clearance to engine and gearbox mountings and radiator.

• Align assembly mountings for engine and gearbox .
• Assembly mounting tightening torques .

• ‒ Install right-hand drive shaft and attach left-hand drive shaft to gearbox:

=> Running gear; Repair group 40; Removing and installing drive shafts

• ‒ Install front exhaust pipe , Removing and installing parts of exhaust system.
• ‒ Installing vane pump for power assisted steering:

=> Running gear; Repair group 48; Assembly overview: Vane pump with hydraulic pipes

• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Install poly V-belt => page 13-11 .

• ‒ Install sound insulation centre, left and right-hand:

=> General body repairs, exterior; Repair group 50; Noise insulation (petrol engine) - Assembly overview

• ‒ Replenishing coolant => page 19-12 .
• ‒ Install secondary air pump.
• ‒ Adapting (matching) engine control unit to throttle valve control part => page 24-43 Adapting components and functions.
• ‒ Carry out a test drive and interrogate fault memory.
• ‒ If the fault memory has been erased or the engine control unit was disconnected from permanent positive, the readiness code must be generated again => page 24-43 , Adapting components and functions.