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Assembly mountings > < Securing engine to assembly stand

Leon Mk2

Notes on installing
Notes on installing
Procedure
Installation is carried out in the reverse order. When installing, note the following:
  WARNING
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 6-speed manual gearbox 02N
–  Clean input shaft splines and lightly grease with grease -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.
–  Align assembly mountings stress-free by rocking.
  Note
Torque settings for engine and gearbox mountings → Chapter.
–  Install pendulum support → Rep. Gr.40
Vehicles with air conditioner
–  Install air conditioner compressor → Rep. Gr.87
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 four wheel drive
–  Install propshaft tube: → Rep. Gr.39
Continuation for all vehicles
–  Install drive shafts → Rep. Gr.40
–  Install power steering vane pump with bracket → Rep. Gr.48
–  Tighten hydraulic line for power steering to right engine bracket. Torque setting: 20 Nm.
–  Install poly V-belt → Chapter.
–  Install air pipes between turbocharger/charge air cooler, charge air cooler/inlet connection.
  Note
When installing ensure that locking lugs engage securely → Chapter.
–  Install front exhaust pipe → Chapter.
–  Install battery and battery tray.
–  Installing radiator → Chapter.
–  Install air filter housing and intake pipe.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Fill with coolant → Chapter.
–  Install sound insulation tray → Rep. Gr.50
Vehicles with automatic gearbox
–  On vehicles with automatic gearbox the gearbox control unit must be additionally adapted → Self-diagnosis for 5-speed automatic gearbox 09B; Rep. Gr. 01.
Continuation for all vehicles
–  Carry out the vehicle system test → Vehicle diagnosis, testing and information system VAS 5051“Guided fault finding”.
–  Finish the vehicle system test so that any incorrect entries created during assembly can be deleted automatically.
–  Generate the readiness code in combination with a road test.
Observe applicable safety precautions during road test → Chapter.
–  Carry out road test.
–  Then carry out the vehicle system test again and correct any faults that have been created.
Torque settings
  A10-0129
Threaded connectionTorque setting
Bolts, nutsM610 Nm
 M715 Nm
 M825 Nm
 M1045 Nm
 M1260 Nm
Deviations 
Front exhaust pipe to exhaust turbocharger25 Nm
Hydraulic line for power steering to engine bracket20 Nm

  Note
Torque settings for engine and gearbox mountings → Chapter.
   

Assembly mountings > < Securing engine to assembly stand