Volkswagen Workshop Service and Repair Manuals

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

• ‒ Check clutch release bearing for wear and renew if necessary.

=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch control; Servicing clutch release mechanism

• ‒ Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, 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.

• ‒ → When installing the engine mounting ensure that the pins on the bonded rubber mounting engage in the engine mounting -arrows-.

Note:

Assembly mounting tightening torques

.

• ‒ Renew pointed bolt for securing shift finger (clean threads in shift finger).
• ‒ Install gear selector mechanism:

=> 5-speed manual gearbox 085; Repair group 34; Servicing selector mechanism (cable selector mechanism); Removing and installing selector mechanism

• ‒ Installing P.A.S. vane pump:

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

• ‒ Installing clutch cable:

=> 5-speed manual gearbox 085; Repair group 30; Servicing clutch mechanism.

• ‒ Installing lock carrier with attachments:

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

• ‒ Electrical connections and routing:

=> Electrical system; Repair group 97

• ‒ Install front exhaust pipe => Page 26-2 , Exhaust manifold, front exhaust pipe and catalyst with attachments.

Engine code AEF

• ‒ Adjust throttle cable => Page 20-17 , Servicing accelerator mechanism.

Continued for all engine codes

• ‒ Fill with coolant => Page 19-12
• ‒ Carry out a test drive and interrogate fault memory:

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