volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Specified torques > < Securing engine on engine and gearbox supportVAS 6095

Golf Mk4

Notes on installing
Notes on installing
Installation is carried out in the reverse order. When installing, note the following:
Procedure
–  Check clutch release bearing for wear and renew slave cylinder with release bearing if necessary → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.30.
–  Lightly grease input shaft splines with „G 000 100“ grease.
–  Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary.
–  When installing engine and gearbox assembly, ensure sufficient clearance to subframe and radiator.
–  Align engine and gearbox mountings → Chapter.
  Note
Specified torques for engine and gearbox mountings → Chapter.
–  Install compact bracket and alternator: → Electrical system; Rep. gr.27
–  Install front exhaust pipe → Chapter.
–  Install front propshaft tube: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.39
–  Install dual catalytic converter → Chapter.
–  Install drive shafts: → Running gear, axles, steering, front and four-wheel drive; Rep. gr.40.
–  Install hydraulic line to hydraulic clutch slave cylinder: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.30
–  Bleed clutch system: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.30
–  Fit selector mechanism: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.34
–  If necessary, adjust Bowden cable mechanism: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.34
–  Install vane pump for power steering: → 02M/02Y 6-speed manual gearbox, four-wheel drive; Rep. gr.30
–  Install poly V-belt → Chapter.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Install centre, left and right insulation trays: → General body repairs, exterior; Rep. gr.50
–  Install intake manifold → Chapter.
–  Install air filter with intake hose → Chapter.
–  Replenish coolant → Chapter.
–  Connect battery.
–  Connect Vehicle diagnosis, testing and information system -VAS 5052-.
–  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.
–  Generate the readiness code in combination with a road test.
–  Then carry out vehicle system test again and rectify any faults which may have occurred.
–  Check headlight adjustment and correct if necessary → Booklet37.
   

Specified torques > < Securing engine on engine and gearbox supportVAS 6095