Volkswagen Golf Variant / Jetta. Manual - part 357

 

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Volkswagen Golf Variant / Jetta. Manual - part 357

 

 

»Engine/transmission assembly« in its installation position us‐

ing the Shop Crane - VAS6100- .

Vibration damper side:
• item 2
Flywheel side:
• item 8

– Remove the subframe bolts -arrows- on the engine.
Vehicles with Manual Transmission:

– Remove the subframe bolts -arrows- on the transmission.
Vehicles with DSG

®

 Transmission:

– Remove the subframe bolts -arrows- on the transmission.
Continuation for All Vehicles:

Note

When removing the »engine/transmission subassembly«, guide

it out carefully to avoid damaging it.

– Lift the »engine/transmission assembly« slightly and remove

it toward the front.

– Separate the transmission from the engine. Refer to

⇒ “1.2 Transmission and Engine, Disconnecting and Assem‐

bling”, page 12

 .

Secure the engine on the Engine and Gearbox Bracket -

VAS6095A- when performing repair work. Refer to

⇒ “1.3 Engine, Securing to Engine and Gearbox Bracket

VAS6095A ”, page 13

 .

1. Engine, Removing and Installing    

11

Transmission and Engine, Disconnect‐

ing and Assembling

Disconnecting:

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

27 ; Starter; Starter, Removing and Installing .

Engine with DSG

®

 Transmission:

– Remove the coolant hoses from the transmission fluid cooler

and seal off the openings.

Continuation for All Types of Transmissions:
– Loosen and free up all electric connections between the trans‐

mission and the engine.

12

le (2 pc.) - 10-222A/12- on the Shop Crane - VAS6100- but do

not lift.

– Remove the upper engine/transmission connecting bolts.
– Before removing the last connecting bolts, support the trans‐

mission with the Shop Crane .

– Remove the lower engine/transmission connecting bolts.
– Separate the transmission from the engine; when doing this,

guide the transmission.

Assembling:

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Assembly is performed in reverse order of removal; at the same

time pay attention to the tightening specifications:
• Vehicles with manual transmission. Refer to ⇒  6-Speed Man‐

ual Transmission 02Q; Rep. Gr.  34 .

• Vehicles with DSG

®

 transmission. Refer to ⇒  6-Speed Dual

Clutch Transmission 02E; Rep. Gr.  34 .

1.3

Engine, Securing to Engine and Gear‐

box Bracket - VAS6095A-

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Special tools and workshop equipment required
♦ Lifting Tackle - 3033-
♦ Engine and Gearbox Bracket VAS6095A - VAS6095A-
♦ Shop Crane - VAS6100-
For performing assembly work, secure the engine using the En‐

gine/Transmission Holder - Universal Mounting - VAS6095/1- to

the Engine and Gearbox Bracket - VAS6095A- .

1. Engine, Removing and Installing    

13

Shop Crane - VAS6100- .

Flywheel side:
• item 4
Vibration damper side:
• item 8
– Fasten the engine to the Engine/Transmission Holder - Uni‐

versal Mounting - VAS6095/1- using the Engine and Gearbox

Bracket - VAS6095A- .

1.4

General Installation Information

WARNING

When doing any assembly work, especially in the engine com‐

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route all lines and wires in their original locations.
♦ For example, for fuel lines, hydraulic lines, EVAP system

lines, coolant and refrigerant lines, brake fluid lines and

vacuum lines.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

Install in reverse order of removal. Note the following:
Servicing the Clutch:
♦ Vehicles with manual transmission. Refer to ⇒  6-Speed Man‐

ual Transmission 02Q; Rep. Gr.  30 .

♦ Vehicles with DSG

®

 transmission. Refer to ⇒  6-Speed Dual

Clutch Transmission 02E; Rep. Gr.  30 .

– Check that the alignment bushings for centering the engine/

transmission are installed inside the cylinder block. Install

them if necessary.

– Make sure there is enough clearance to the subframe and ra‐

diator when installing the »engine/transmission assembly«.

– Adjust the subframe mount. Refer to

⇒ “2.3 Subframe Mount, Adjusting”, page 19

 .

Note

Subframe mount tightening specifications. Refer to

⇒ “2.1 Overview - Subframe Mount”, page 17

 , Overview -

Subframe Mount.

Electrical connections and routing. Refer to ⇒  Electrical

Equipment; Rep. Gr.  97 .

14

 

 

 

 

 

 

 

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