Volkswagen Workshop Service and Repair Manuals > Golf Mk5 > Power unit | 4-cylinder injection engine, 2005? | Engine assy,cylinder block,crankcase | Removing and 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 types of lines (e.g. for fuel, hydraulics, active charcoal filter system, coolant, 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 centering 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 control 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 tension free by shaking. If necessary, loosen engine mounting on body.

–	Install pendulum support.

Note

t	Torque settings for engine and gearbox mountings → Chapter.

t	Electrical connections and routing → Electrical system; Rep. Gr.97.

–	Install right-hand drive shaft and bolt or slot left-hand drive shaft onto gearbox → Running gear; Rep. Gr.40.

Vehicles with manual gearbox

–	Install selector mechanism and adjust mechanism if necessary → Manual gearbox; Rep. Gr.34.

–	Install slave cylinder for hydraulic clutch → Manual gearbox; Rep. Gr.30.

Vehicles with automatic gearbox

–	Install selector lever cable and adjust if necessary → Automatic gearbox 09G; Rep. Gr.37.

All vehicles (continued):

–	Install air conditioner compressor → Heating, air conditioning; Rep. Gr.87.

–	Install poly V-belt → Chapter.

–	Install sound insulation tray → General body repairs, exterior; Rep. Gr.50.

–	Install plenum chamber bulkhead → General body repairs, exterior; Rep. Gr.50.

–	Fill coolant system with coolant → Chapter.

–	Adapt engine control unit → Vehicle diagnosis, testing and information system VAS 5051.

–	Carry out road test and then read fault memory.

Torque settings

Volkswagen Workshop Service and Repair Manuals