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Align unit mounting for engine and gearbox > < Procedure

Octavia Mk1

Installing the engine
Installing the engine
Special tools and workshop equipment required
t  Workshop crane (e.g. -V.A.G 1202 A-)
t  Catch pan for workshop crane (e.g. -VAS 6208-)
t  Torque wrench
t  Engine/gearbox jack (e.g. -V.A.G 1383 A-)
t  Pliers for spring strap clips
t  Ladder (e.g. -VAS 5085-)
t  Engine mount -T10012-
t  Bushing -T30010 (VW 540/1B)-
t  Engine and gearbox mount -MP1-202-
t  Assembly stand -MP9-101-
t  Lifting device -MP9-201 (2024A)-
t  Grease -G 000 100-
t  Hot screw paste -G 052 112 A3-
t  Cable strap
t  Adhesive tape
  Note
t  Always replace the seals and gaskets during assembly work.
t  Replace the self-locking nuts and screws.
t  Clean the threaded holes into which screws were screwed in with locking agent and remove all hardened locking agent residues.
t  Coat stud bolts of exhaust turbocharger with hot bolt paste -G 052 112 A3- before installing.
t  Tightening torques → Chapter.
t  Assembly bracket → Chapter.
Installation occurs in reverse order for removal, while paying attention to the following:
–  Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; insert if necessary.
   
–  Check whether the intermediate plate has been inserted on the sealing flange and rests on the dowel sleeves -arrows-.
–  Slightly grease the clutch release bearing, guide bushing for clutch release bearing and serration of the drive shaft with grease -G 000 100 -.
–  If necessary check the centering of the clutch disc.
–  Install slave cylinder → 5-Speed Manual Gearbox 02J → Rep. Gr.30.
–  Attach shift mechanism and set → 5-Speed Manual Gearbox 02J → Rep. Gr.34.
–  When installing the engine/gearbox units, ensure clearance to the subframe as well as to the radiator.
   Run pressure line of power-assisted steering past the gearbox.
–  Align engine and gearbox mount → Chapter.
When tightening up the bolts for the engine and gearbox mount, the engine support and the gearbox mounting bracket must be resting fully against the mount.
–  Install alternator → Electrical System → Rep. Gr.27.
–  Install AC compressor → Heating, Air Conditioning → Rep. Gr.87.
–  Install vane pump for power-assisted steering → Chassis → Rep. Gr.48.
–  Install coolant hose → Chapter.
–  Electrical connections and proper routing → Current flow diagrams and Fitting locations.
–  Install secondary air pump with bracket → Chapter.
–  Check oil level before starting the engine →  Octavia.
–  When the battery is disconnected and reconnected, carry out additional operations → Electrical System → Rep. Gr.27.
–  Make a test drive and interrogate the fault memory → Vehicle diagnosis, testing and information system VAS 5051.
  Note
If a charger is used as a starting aid there is the risk of damaging the control units on the vehicle.
  A10-0129

Align unit mounting for engine and gearbox > < Procedure