Volkswagen Golf Variant / Jetta. Manual - part 367

 

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Volkswagen Golf Variant / Jetta. Manual - part 367

 

 

Do not open the A/C system refrigerant circuit.

– Remove the A/C compressor from the sub-assembly bracket

and secure it to the lock carrier.

– Remove the idler rollers -1 and 2- and remove the bolt on the

toothed belt guard -arrow-.

– Remove the bolts -6 to 1- and remove the sub-assembly

bracket.

Installing
Install in reverse order of removal. Note the following:
♦ Make sure there are alignment sleeves inside the sub-assem‐

bly bracket and replace any that are missing.

♦ Replace bolts, which have been tightened to torque.

– Tighten the bolts in sequence -1 to 6-. Tightening specification

-item 5- 

⇒ Item 5 (page 42)

 .

– Install the generator. Refer to ⇒  Electrical Equipment; Rep.

Gr.  27 .

– Install the high pressure pump. Refer to

⇒ “3.8 High Pressure Fuel Pump, Removing and Installing”,

page 325

 .

– Install the engine bracket. Refer to

⇒ “1.7 Engine Bracket, Removing and Installing”, page 52

 .

1. Engine, Disassembling and Assembling    

51

Engine Bracket, Removing and Instal‐

ling

Caution

♦ Clean the oil channels carefully
♦ Replace the oil spray jets
♦ Replace the oil cooler
♦ Replace the oil filter.

Removing

WARNING

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

partment,  pay  attention  to  the  following  due  to  the  limited

space.

♦ Route lines of all types (for example for fuel, hydraulic,

EVAP canister system, coolant and refrigerant, brake flu‐

id, vacuum) and electrical wiring so that the original path

is followed.

♦ Make sure that there is sufficient clearance to all moving

or hot components.

There is a risk of breaking for work on or near the vehicle align‐

ment.

– Remove the engine cover. Refer to

⇒ “1.4 Engine Cover, Removing and Installing”, page 90

 .

– Remove the intake hose between the Mass Airflow Sensor -

G70- and the intake scoop. Loosen the spring clamps using

the Hose Clip Pliers - VAS6362- .

– Remove the filler neck from the windshield and headlamp

washer fluid reservoir. Refer to ⇒  Electrical Equipment; Rep.

Gr.  92 ; Windshield Washer System; Washer Fluid Reservoir,

Removing and Installing .

– Remove the coolant expansion tank from the body (the coolant

lines remain connected).

– Remove the fuel filter (the fuel lines remain connected).
– Remove the right front wheel housing liner. Refer to ⇒  Body

Exterior; Rep. Gr.  66 ; Wheel Housing Liner .

All Vehicles Except for Jetta from MY 2011.
– Support the engine in the installation position. Refer to

⇒ “2.3 Subframe Mount, Adjusting”, page 19

 .

52

⇒ “3.5 Engine, Supporting in Installation Position”, page 31

 .

Continuation for All Vehicles

Note

The subframe mount bolts may only be loosened when the

engine is supported with the Engine Support Bridge -

10-222A- .

The engine bracket may only be loosened only when the en‐

gine mount is removed.

– Loosen the bolts -4- on the engine mount -5-.
– Then remove the engine mount -5- bolts in the following se‐

quence:

1.

Bolts -3-

2.

Bolts -1 and 2-

3.

Bolts -4-

– Remove the engine mount -5-.

WARNING

Make sure that no components/hoses are damaged, stretched

or torn when lifting or lowering the engine using the Engine

Support Bridge - 10-222A- .

Note

The bolt -1- can be reached through an opening in the wheel

housing. If necessary, raise and lower the engine with the spindle

on the Engine Support Bridge - 10-222A- to remove or install the

bolts -2- and -3-.

– Remove the engine bracket bolts in the sequence -3 to 1-.

1. Engine, Disassembling and Assembling    

53

Caution

Always use the correct tightening sequence and specifications

for the engine bracket bolts. Otherwise tension could develop

in the engine bracket and break it.

• Subframe mount tightening specifications. Refer to

⇒ “2 Subframe Mount, except Jetta from MY 2011”, page 17

 .

• Subframe mount tightening specifications. Refer to

⇒ “3 Assembly Mounts, Jetta from 2011”, page 23

 .

Install in reverse order of removal. Note the following:
– Install the engine bracket from above.

Note

The bolt -1- can be reached through an opening in the wheel

housing. If necessary, lift or lower the engine with the spindle for

the Engine Support Bridge - 10-222A- to remove or install the

bolts -2- and -3-.

– Tighten the new bolts hand-tight in the sequence -1 to 3-.
– Tighten the bolts in the sequence -1 to 3- to the tightening

specification -item 3- 

⇒ Item 3 (page 23)

 .

– Install the engine mount -5- and tighten the new bolts to the

tightening specification in the following sequence:

1.

Bolts -3-

2.

Bolts -1 and 2-

3.

Using the spindle, bring the engine bracket into position on

the engine mount -5-.

1.

Tighten the bolts -4-.

– Checking the engine-subframe mount adjustment, except Jet‐

ta from MY 2011. Refer to

⇒ “2.2 Engine-Subframe Mount Adjustment, Checking”, page

19

 .

– Checking the engine-subframe mount adjustment, for Jetta

MY from 2011. Refer to

⇒ “3.7 Subframe Mount, Checking Adjustment”, page 36

 .

Further installation is the reverse order of removal. Note the fol‐

lowing:
• Check the fuel lines for secure fit.
• Do not interchange the supply and return lines (return lines are

blue or have blue markings, supply lines are black).

54

 

 

 

 

 

 

 

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