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Assembly mountings > < Securing engine to assembly stand

Leon Mk2

Notes on installing
Notes on installing
Installation is carried out in the reverse order. When installing, note the following:
  Caution
When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:
t  Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
t  Ensure that there is sufficient clearance to all moving or hot components.
–  Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary.
   
–  Hook intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Vehicles with 5-speed manual gearbox 006
–  Clean input shaft splines and lightly grease with grease -G 000 100-.
–  Check clutch and clutch operating mechanism and install → Rep. Gr.30.
Vehicles with 6-speed manual gearbox 02N
–  Clean input shaft splines and lightly grease with G 000 100.
–  Check clutch and clutch operating mechanism and install → Rep. Gr.30.
Continuation for all vehicles
–  Screw in all bolts on assembly mountings by hand approx. 5..6 turns.
Vehicles with engine code AJH
  Note!
  A10-0129
Before inserting bolts for assembly mounting, bracket -B- must be installed and bolted; torque settings for bracket → Chapter.
Continuation for all vehicles
–  Align assembly mountings stress-free by rocking.
  Note!
Torque settings for engine and gearbox mountings → Chapter.
Vehicles with 5-speed manual gearbox 006
–  Connect pipe/hose to slave cylinder and secure with clip → Rep. Gr.30
–  Attach operating cables to gearbox, adjust if necessary → Rep. Gr.34
Vehicles with 6-speed manual gearbox 02N
–  Connect pipe/hose to slave cylinder and secure with clip → Rep. Gr.30
–  Attach operating cables to gearbox, adjust if necessary → Rep. Gr.34
Vehicles with 4-speed automatic gearbox 099
–  Install selector lever cable on gearbox, adjust if necessary → Rep. Gr.37
Vehicles with 5-speed automatic gearbox 09B
–  Install selector lever cable on gearbox, adjust if necessary → Rep. Gr.37
Continuation for all vehicles
–  Install front exhaust pipe → Chapter, Front exhaust pipe and catalytic converter with attachments.
–  Install drive shafts → Rep. Gr.40
–  Install pendulum support → Rep. Gr.40
–  Install power assisted steering vane pump → Rep. Gr.48.
–  Tighten hydraulic line for power assisted steering on right engine bracket; torque setting: 20 Nm.
Vehicles with air conditioner
–  Install air conditioner compressor → Rep. Gr.87
Continuation for all vehicles
–  Install poly-V-belt → Chapter.
Vehicles with engine code AJH
–  Install air pipes between turbocharger/charge air cooler, turbocharger/air filter and charge air cooler/throttle valve control module → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH.
–  Install intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AJH.
–  Install pressure hose between secondary air pump motor -V101- and combination valve → Chapter, Removing and installing parts of the secondary air system.
–  Adjusting accelerator cable → Chapter, Repairing accelerator mechanism.
Vehicles with engine code AWC
–  Install air pipes between turbocharger/charge air cooler, turbocharger/air filter and charge air cooler/throttle valve control module → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC.
–  Install intake hose → Chapter, Removing and installing parts of the charge air cooling system: engine code AWC.
–  Install pressure hose between secondary air pump motor -V101- and combination valve → Chapter, Removing and installing parts of the secondary air system.
Continuation for all vehicles
–  Install air filter → Rep. Gr.24.
–  Install battery and battery tray.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
Filling with new coolant → Chapter.
–  Install sound insulation tray → Rep. Gr.50
Vehicles with engine code AJH
–  Carry out a test drive and interrogate fault memory: → Rep. Gr.01
–  Co-ordinate engine electronics control unit with throttle valve control module → Rep. Gr.24
Vehicles with engine code AWC
–  Carry out a test drive and interrogate fault memory: → Rep. Gr.01
–  Adapt engine control unit to throttle valve control module and exhaust gas recirculation valve → Rep. Gr.24
Vehicles with 5-speed automatic gearbox 09B
–  On vehicles with an automatic gearbox the gearbox control unit must be additionally adapted → Self-diagnosis for 5-speed automatic gearbox 09B; Rep. Gr.01.
Torque settings
  N10-0165
Threaded connectionTorque setting
Bolts, nutsM610 Nm
 M715 Nm
 M825 Nm
 M1040 Nm
 M1260 Nm
Deviations 
Hydraulic line to engine bracket20 Nm
Starter to gearbox and engine45 Nm
Front exhaust pipe to exhaust turbocharger25 Nm

  Note!
Torque settings for engine and gearbox mountings → Chapter.
   

Assembly mountings > < Securing engine to assembly stand