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Assembly bracket > < Securing the engine to the assembly stand

Octavia Mk2

Installing the engine
Installing the engine
Special tools and workshop equipment required
t  Double ladder, e. g. -VAS 5085 -
t  Pliers for spring strap clamps
t  Grease -G 000 100-
t  Cable strap
l  Fit engine and gearbox using engine mount to the engine/gearbox jack.
Work procedure
Installation is carried out in the reverse order. Pay attention to the following:
  Caution
When undertaking all assembly work, particularly in the engine compartment due to its cramped construction, please observe the following:
t  Lay lines of all kinds (e.g. for fuel, hydraulic fluid, the active charcoal container-unit, cooling fluid and refrigerant, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established.
t  In order to avoid damage to the cables, ensure that there is adequate free access to all moving or hot components.
  Note
t  All cable straps should be fitted on again in the same place when installing.
t  Secure all hose connections with hose clamps → Electronic Catalogue of Original Parts.
t  When performing installation work replace the self-locking nuts and screws.
t  Replace screws which have been tightened to a torquing angle as well as gasket rings and seals.
Observe all safety measures and notes for assembly work on the fuel, injection and ignition system and the charge air system as well as rules for cleanliness → Chapter.
   
–  Ensure that the intermediate plate has been inserted on the sealing flange and is pushed onto the dowel sleeves -arrows-.
For vehicles with manual gearbox
–  Check the centering of the clutch disc → Manual Gearbox; Rep. Gr.30.
–  Inspect clutch release bearing for wear, replace if necessary.
–  Check and install clutch and clutch control
–  Lightly lubricate the drive shaft serration with grease -G 000 100-.
For vehicles with automatic gearbox DSG
  S13-0541
–  Replace the needle bearing -arrow- in the crankshaft → Chapter.
–  Attach the selector lever control cable at the gearbox → Gearbox; Rep. Gr.34.
Continued for all vehicles
–  Screw on gearbox to engine → Anchor.
–  When installing the engine/gearbox unit, ensure clearance to the assembly carrier, AC compressor as well as to the radiator fans.
–  Tighten the new screws by hand for attaching the engine/gearbox unit at the engine and gearbox mounts.
–  Adjust assembly bracket → Chapter and tighten screws → Chapter.
  Note
When setting the assembly bracket for engine/gearbox unit, do not support it with the supporting device -MP9-200 (10-222A)-.
–  Install pendulum support → Chapter.
–  Install drive shafts → Chassis; Rep. Gr.40.
–  Install AC compressor → Chapter.
–  Install the V-ribbed belt → Chapter.
–  Install slave cylinder → Manual Gearbox; Rep. Gr.30.
–  Attach shift mechanism and adjust if necessary → Manual Gearbox; Rep. Gr.34.
–  Install the engine wiring harness and connect to the engine control unit → Chapter.
–  Install exhaust system → Chapter.
–  Install the battery and pay attention to the necessary work after re-connecting the battery → Electrical System; Rep. Gr.27.
–  Checking the oil level →  Octavia II.
–  Top up and bleed cooling system → Chapter.
–  Interrogate all fault memories and delete all fault entries, which are caused by removing and installing the engine → Vehicle diagnosis, testing and information system VAS 5051.
   After deleting the fault memory of the engine control unit the readiness code must be re-generated.
–  Perform a test drive.
–  Then perform a vehicle system test and if necessary eliminate the resulting faults.
Tightening torques
  N34-10979
Component Nm 
Screws/nutsM69 
 M713
 M820
 M1040
 M1270
deviations: 
Engine/gearbox connecting screws → Gearbox; Rep. Gr.34
Screws for assembly bracket → Chapter

   

Assembly bracket > < Securing the engine to the assembly stand