Notes On Installing - Volkswagen Golf 2004 Workshop Manual

– Attach lifting tackle -VAS 2024A- as follows and lift from engine
and gearbox jack -V.A.G 1383/A- using workshop crane.
Belt pulley end: 1st hole in hook rail at position 1
Flywheel end: 4th hole in hook rail at position 8
WARNING
The hooks and locating pins must be secured with locking pins.
Note
The positions marked 1...4 on the bar must be towards the
♦
pulley end.
The holes in the hook rails are counted up from the hook.
♦
– Secure engine on engine and gearbox support -VAS 6095/1-
using universal mounting -VAS 6095- .
1.3

Notes on installing

Installation is carried out in the reverse order. When installing,
note the following:
– Check clutch release bearing for wear and renew if necessary.
– Lightly grease input shaft splines with G 000 100 grease.
– Check whether dowel sleeves for centring engine and gearbox
are in cylinder block and install if necessary.
– Rock engine to align engine mountings stress-free.
Note
Specified torques for engine and gearbox mountings
♦
⇒ page 14 .
Electrical connections and routing ⇒ Electrical system; Rep.
♦
gr. 97 .
– On vehicles with particulate filter install subframe and steering
⇒ Running gear, axles, steering; Rep. gr. 40 .
– Install pendulum support.
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing drive shafts .
– Vehicles with no particulate filter, install front exhaust pipe
⇒ page 277 .
– Install poly V-belt ⇒ page 16
– Install hydraulic line for hydraulic clutch ⇒ 6-speed manual
gearbox 02Q; Repair group 30; Repairing clutch mechanism;
Assembly overview - hydraulic system .
– Install selector mechanism and, if necessary, adjust gear se‐
lector cables ⇒ 6-speed manual gearbox 02Q; Rep. Gr. 34;
Repairing selector mechanism .
– Replenish coolant ⇒ page 134
Golf 2004 ➤ , Golf Plus 2005 ➤ , Passat 2006 ➤ , Touran 2003 ➤
4-cylinder diesel engine (2.0 l engine, 4 valve) - Edition 02.2011
.
.
1. Removing and installing engine
13