Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 647
– Unclip the right engine cover mount -1-.
– Hook the Engine Sling - 2024A- to the engine and to the Shop
Crane - VAS6100- .
– To be aligned to the center of gravity of the engine assembly,
the hole rails must be inserted as shown in the illustration.
– Secure the mounting hooks and pins on the engine support
bridge using securing pins -arrows-.
– Lower the engine from the Engine and Gearbox Jack -
VAS6931- using the Shop Crane - VAS6100- .
– Remove the transmission alignment sleeve and secure the
transmission side of the engine on the Engine And Transmis‐
sion Holder - VAS6095- .
1.4
Engine, Installing
Caution
This procedure contains mandatory replaceable parts. Refer
to component overview prior to starting procedure.
Mandatory Replacement Parts
♦ Bolts - Transmission Mount
♦ Bolts - Engine to Transmission
Tightening Specifications
Note
♦
The tightening specifications apply only to lightly greased,
oiled, phosphated or blackened nuts and bolts.
♦
Additional lubricants, such as engine or transmission oil are
permissible, although lubricants containing graphite are not.
♦
Do not use any ungreased parts.
♦
Tightening specification tolerance: ±15%.
Component
Nm
Bolts and nuts
M6
10
M7
15
M8
20
M10
40
M12
65
♦ Refer to
⇒ “2.1 Overview - Subframe Mount”, page 29
.
♦ Securing engine to transmission. Refer to ⇒ Rep. Gr. 34 ;
Transmission, Removing and Installing; Transmission Tight‐
ening Specifications .
Procedure
Note
♦
Replace the bolts that were tightened with an additional turn.
♦
Replace the self-locking nuts and bolts, sealing rings, seals
and O-rings.
♦
The hose connections as well as the air guide pipes and hoses
must be free of oil and grease before installing.
♦
Secure hose connections with standard production clamps.
Refer to the Parts Catalog.
♦
During installation, all cable ties must be installed at the same
location.
– Install intermediate plate. Refer to
⇒ Fig. ““Installing Intermediate Plate”“ , page 58
.
Note
The illustration shows a vehicle with DSG
®
transmission.
– If the alignment sleeves -A- for centering the engine and trans‐
mission are missing inside the cylinder block, then install the
sleeves.
Vehicles with a Manual Transmission
– If a needle bearing is installed in the crankshaft, remove the
needle bearing. Refer to
⇒ “3.4 Crankshaft Needle Bearing, Replacing”, page 65
– If the clutch release bearing is worn, replace it. Refer to ⇒
Manual Transmission; Rep. Gr. 30 ; Clutch Mechanism;
Clutch Release Mechanism, Servicing .
– Lightly lubricate the transmission input shaft splines. Refer to
the Parts Catalog.
– Check the clutch plate alignment.
Vehicles with DSG
®
Transmission
– If no needle bearing is installed in crankshaft, install needle
bearing. Refer to ⇒ Engine Mechanical, Fuel Injection and
Ignition; Rep. Gr. 13 ; Crankshaft; Crankshaft Needle Bearing,
Replacing .
Continuation for All Vehicles
– Attach transmission to engine.
– Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 ; Starter; Starter, Removing and Installing .
– Guide the engine/transmission assembly into the body.
– Install the bolts -arrows- for the engine mount by hand all the
way.
– Install the bolts -arrows- for the transmission mount by hand
until it is in position.
Note
Only tighten the bolts to the specification when installing the sub‐
frame mount. Refer to
⇒ “2.1 Overview - Subframe Mount”, page 29
.
– Remove the Engine/Gearbox Jack - Engine Support -
T10359A- from the engine.
– Install drive axles. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Drive Axle; Drive Axle, Removing and Installing .
Vehicles with a Manual Transmission
– Install the clutch slave cylinder. Refer to ⇒ Controls, Housing;
Rep. Gr. 34 ; Selector Mechanism; Selector Mechanism, Re‐
moving and Installing .
– Install the cables with the cable bracket. Refer to ⇒ Manual
Transmission; Rep. Gr. 30 ; Clutch Mechanism; Component
Location Overview - Clutch Mechanism .
Vehicles with DSG
®
Transmission
– Install and adjust the selector lever cable. Refer to ⇒ Rep. Gr.
34 ; Selector Mechanism; Overview - Selector Mechanism .
Continuation for All Vehicles
– Install the Air Conditioning (A/C) compressor. Refer to ⇒
Heating, Ventilation and Air Conditioning; Rep. Gr. 87 ; A/C
Compressor; Overview - A/C Compressor Power Unit .
– Install the ribbed belt. Refer to
⇒ “1.2 Ribbed Belt, Removing and Installing”, page 46
– Adjust the subframe mount. Refer to
⇒ “2.6 Subframe Mount, Adjusting”, page 36
– Install the battery tray. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Overview - Battery .
– For the electrical connections and wiring routing. Refer to ⇒
Electrical Equipment; Rep. Gr. 97 ; Relay Carriers, Fuse Pan‐
els and E-Boxes; Component Location Overview - Relay Car‐
riers, Fuse Panels and E-Boxes and ⇒ Wiring diagrams,
Troubleshooting & Component locations.
– Install the air filter housing. Refer to
⇒ “3.2 Air Filter Housing, Removing and Installing”,
.
– Install the engine cover. Refer to
⇒ “3.1 Engine Cover, Removing and Installing”, page 38
.
– Check the oil level.
– Attach the coolant hoses to the heater core. Refer to
⇒ Fig. ““Connect the Coolant Hose to the Coupling”“ ,
.
– Fill with coolant. Refer to
.
Note
Do not reuse used coolant.
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