Volkswagen Golf/Jetta 2 manual

Engine ancillary components - refitting
Engine repair procedures - 1.6 and 1.8 litre 8 valve / Engine ancillary components - refitting

1 On automatic transmission models, refit the driveplate together with any shims originally located between the crankshaft and the plate.

Fit the washer on the transmission side of the driveplate, ensuring that the chamfered side of the washer faces towards the driveplate.

Use new bolts and tighten them to the specified torque setting then using vernier calipers, check the distance between the driveplate and the cylinder block as shown (see illustration) at three positions. If the clearance is not between 30.5 and 32.1 mm, remove the driveplate, fit shims of suitable thickness between the driveplate and the crankshaft, then refit the driveplate assembly and recheck the clearance. If the engine is a new or reconditioned short block replacement, check that the bore in the rear end does not contain a needle roller bearing. If it does, then remove the bearing as this is for manual gearbox models only.

36.1 Checking driveplate-to-cylinder block dimension (A) using vernier
36.1 Checking driveplate-to-cylinder block dimension (A) using vernier calipers

2 On manual gearbox models, refit the clutch together with the intermediate plate.

3 Refit the inlet and exhaust manifolds.

4 Refit the coolant pump and all hoses to the engine.

5 Refit the alternator and drivebelt.

6 Refit the oil pressure switch to the cylinder head or filter mounting as applicable, using a new washer or O-ring. Tighten to the specified torque.

7 Fit the oil filter mounting to the cylinder block, together with a new gasket and tighten the bolts. On models fitted with an oil cooler, refit the supply and return hoses to their correct unions.

8 Fit the oil filter.

9 Refit the distributor.

10 On carburettor models, refit the fuel pump.

11 On fuel injection models, refit the warm-up valve (if the hoses were disconnected) .

12 Refit the coolant temperature sender unit and the thermotime switch with new O-rings.

13 Refit the spark plugs, if not already done.

14 Refit the gearbox/transmission to the engine.

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