Notes on installing
WARNING: This page is about a different car, the 2004 Volkswagen R32. However, it is still accessible from the selected car via links, so may be relevant.
Installation is performed in reverse order of removal. Note the following:
Work procedure
- Check 6 Spd. Manual Transmission 02Y All Wheel Drive clutch throw-out bearing, if necessary replace slave cylinder with throw-out bearing: Refer to 30 - CLUTCH
- Clean drive shaft splines and lightly grease with "G 000 100".
- Check whether dowel sleeves for centralizing engine/transmission are in cylinder block, install if necessary.
- When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
- Align engine and transmission mountings, refer to Engine and transmission mounts, aligning under Engine and transmission mounts, aligning .
NOTE:
- Torque settings for assembly mountings, refer to Assembly mounting .
- Install compact bracket and generator: Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- Install front exhaust pipe.
- Install front driveshaft tube: Refer to 39F - FINAL DRIVE, FRONT DIFFERENTIAL or 39R - FINAL DRIVE, REAR DIFFERENTIAL
- Install double catalytic converter, refer to Exhaust system components, removing and installing .
- Install drive axles: Refer to 40 FRONT SUSPENSION
- Install hydraulic line to hydraulic clutch slave cylinder: Refer to 30 - CLUTCH
- Bleed clutch system: Refer to 30 - CLUTCH
- Install shift mechanism: Refer to 34 - MANUAL TRANSMISSION - CONTROLS, HOUSING
- If necessary, adjust selector lever cable: Refer to 34 - MANUAL TRANSMISSION - CONTROLS, HOUSING
- Install power steering pump: Refer to 30 - CLUTCH
- Install ribbed belt, refer to Ribbed belt, removing and installing under Ribbed belt, removing and installing .
- Electrical connections and routing: Refer to Electrical Wiring Diagrams, Troubleshooting and Component Locations
- Install center sound insulation pan, along with left and right sides: Refer to 50 BODY, FRONT
- Install intake manifold, refer to Cylinder head cover, removing and installing .
- Install the air filter with intake tube, refer to Air filter, assembly overview .
- Fill with coolant, refer to Cooling system, draining and filling under Cooling system, draining and filling .
- Adapt Engine Control Module (ECM) to throttle valve control module "Guided functions"
- Perform a test drive and check all Fault memories.
- Check headlight adjustment and adjust if necessary: Refer to Repair Manual, Maintenance