Monday, May 3, 2010

VW Golf IV/Jetta Diesel-Motor Supplemental Installation Information

Overview of process
1. Mount Heating Unit
2. Run wiring harness into vehicle
3. Connect coolant hoses
4. Mount fuel pump and run fuel lines
5. Route wires inside vehicle and make final connections
6. Tap fuel via sending unit.

Mount Heating Unit
• Air Box Removal
o Disconnect MAF
o Disconnect air intake tube to MAF
o Remove screws to air box
o Remove snorkel
• Battery Removal
o Remove covers behind left headlamp
o Remove bolt and metal battery clamp
o Remove positive and negative battery terminals
o Remove fuse holder / wiring chase behind battery
o Remove SHROUD around left headlamp
• Access to Plenum and water-tight box (for MY 2002 skip this step)
o Remove both wiper arms
o Remove plastic cover/cowling
o Remove windshield wiper motor
o Purchase extra wiring grommet
• Remove Bumper
o Remove screws from the front of inside wheel liner
o Remove side markers and bulbs
o Remove front grill and lower bumper grills
o Remove all bumper bolts and remove front bumper
o Re-locate horns if necessary
• Mount Metal coolant pipes
o Loosen OEM bolt as per instructions
o Use part/position 19, M6X20mm with part/position 21 and part/position 17
o Insert metal cooling lines from OUTSIDE the car to the inside of the engine bay. There is not enough room in the engine bay to go from the inside out.

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