Volkswagen Workshop Service and Repair Manuals

Installing engine 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. –  Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft 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. Align engine mountings as follows:

t  There must be a distance -a- of at least 10 mm between engine support and longitudinal member (right side). t  The side surface of the engine support -2- should be located parallel to the support arm -1-.

t  Ensure that edges of support arm on gearbox assembly mounting -2- and gearbox support -1- are parallel on gearbox side. –  Install pendulum support.   Note Specified torques for assembly mountings → Chapter. –  Install drive shafts → Running gear, axles, steering; Rep. gr.40. –  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 hydraulic clutch slave cylinder: → 6-speed manual gearbox 02S; Rep. gr.30. –  Attach selector mechanism: → 6-speed manual gearbox 02S; Rep. gr.34. –  Install engine splash protection. –  Replenish coolant → Chapter. –  Install air filter → Chapter. –  Install battery and battery tray → Electrical system; Rep. gr.27. –  Connect battery → Electrical system; Rep. gr.27. Engine cover ► November 2006

–  Place vacuum hose -2- onto vacuum reservoir union -1-.   Note Ensure that the vacuum hose is locked onto the union -2-.

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages. Engine cover November 2006 ►

–  Push engine cover panel down at points -1- in direction of -arrow- until it engages. –  Fit vacuum hose onto connection -arrow-. –  Connect Vehicle diagnosis tester. –  Erase learnt values and adapt engine control unit to regulating value control unit and 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.