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Volkswagen Workshop Service and Repair Manuals

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Assembly mountings > < Securing engine to assembly stand

Golf Mk5

Installing engine
Installing engine
Assembly mountings → Chapter.
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.
–  Insert new dowel sleeves in cylinder block for centring engine and gearbox.
   
–  Hook intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Vehicles with manual gearbox:
–  Lightly grease input shaft splines with grease -G 000 100-.
–  Check clutch and clutch actuation mechanism and install → Manual gearbox; Rep. gr.30.
Continuation for all vehicles:
–  When installing engine and gearbox assembly, ensure sufficient clearance to subframe and radiator.
–  Align engine mountings as follows:
  A10-0129
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-.
–  Install pendulum support.
  Note
t  Specified torques for assembly mountings → Chapter.
t  Electrical connections and routing → Electrical system; Rep. gr.97.
–  Install front exhaust pipe.
–  Install right and left drive shaft → Running gear, axles, steering; Rep. gr.40.
Vehicles with manual gearbox:
–  Install selector mechanism and adjust if necessary → Rep. gr.34.
–  Reconnect pipe/hose line to slave cylinder breather → Manual gearbox; Rep. gr.30.
Vehicles with automatic gearbox:
–  Install selector lever cable and adjust if necessary → Automatic gearbox 09G; Rep. gr.37.
Continuation for all vehicles:
–  Install noise insulation → General body repairs, exterior; Rep. gr.50.
–  Install plenum chamber bulkhead (Golf and Eos only), plenum chamber cover and wiper arms → Electrical system; Rep. gr.92.
–  Connect battery and observe required procedures after connecting battery → Electrical system; Rep. gr.27.
–  Fill coolant system with coolant → Chapter.
–  Connect Vehicle diagnosis, testing and information system -VAS 5051B-.
–  Read all fault memories and clear all fault entries that have been created during assembly.
–  Carry out a road test.
–  Then carry out a vehicle system test and correct any faults that have been created.
  Note
If the fault memory was cleared, the readiness code must be generated → Vehicle diagnostic tester„Guided functions“.
Specified torques:
  A10-1661
Threaded connection Specified torque
Bolts, nutsM610 Nm
 M715 Nm
 M825 Nm
 M1040 Nm
 M1260 Nm

   

Assembly mountings > < Securing engine to assembly stand