Volkswagen Workshop Service and Repair Manuals

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

• ‒ Check clutch release bearing for wear, renew if necessary.
• ‒ Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
• ‒ Check whether the dowel sleeves for centring engine/gearbox are in the cylinder block and install if necessary.
• ‒ When swinging the assembly in, ensure that clearance exists between the drive shafts.
• ‒ Align engine mountings stress-free by rocking, if necessary loosen engine mountings to body.

Note:

Assembly mounting tightening torques

.

• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Install drive shafts:

=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft

• ‒ Install front exhaust pipe => Page 26-1, Removing and installing parts of exhaust system.
• ‒ Install hydraulic clutch slave cylinder:

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

• ‒ Install gear selector mechanism:

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

• ‒ If necessary adjust selector cables:

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

• ‒ Installing P.A.S. vane pump:

=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic lines; Removing and installing power steering vane pump.

• ‒ Installing lock carrier with attachments:

=> General body repairs, exterior; Repair group 50; Body, front; Removing and installing lock carrier with attachments.

• ‒ Fill with coolant => Page 19-11
• ‒ Install ribbed belt => Page 13-16.
• ‒ Install air mass meter.
• ‒ Install air filter/turbocharger, charge air cooler/turbocharger and charge air cooler/intake connecting flange connecting pipes.
• ‒ Hook charge air cooler/turbocharger connecting pipe to sump.
• ‒ Install insulation tray:

=> General body repairs exterior; Repair group 50; Body front; Assembly overview

• ‒ Check headlight adjustment and adjust if necessary:

=> Maintenance booklet

• ‒ Carry out a test drive and interrogate fault memory:

=> Repair group 01; Self-diagnosis; Interrogating and erasing fault memory