volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

Assembly mountings > < Securing engine to assembly stand
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  To avoid damage to lines, ensure sufficient clearance to all moving or hot components.
–  Check clutch release bearing for wear and renew if necessary.
–  Lightly lubricate clutch release bearing, release bearing guide sleeve and splines on input shaft with grease -G 000 100-.
–  Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary.
–  When swinging engine in, ensure that there is clearance between drive shafts.
–  Align engine mountings stress-free by rocking, if necessary loosen engine mountings to body.
  Note
Torque settings for engine and gearbox mountings → Chapter.
–  Electrical connections and routing → Rep. Gr.97.
–  Install drive shafts → Rep. Gr.40.
–  Install front exhaust pipe → Chapter.
–  Install hydraulic clutch slave cylinder → Rep. Gr.30
–  Install gear selector mechanism → Rep. Gr.34.
–  Adjust selector cable, if necessary → Rep. Gr.34.
–  Install power assisted steering vane pump → Rep. Gr.48.
–  Install lock carrier with attachments → Rep. Gr.50
–  Fill with coolant → Chapter.
–  Install poly V-belt → Chapter.
–  Install air mass meter.
–  Install connecting pipes between air mass meter and turbocharger and between charge air cooler/turbocharger and intake connecting flange/turbocharger.
–  Fit connecting pipe between charge air cooler and turbocharger on sump.
–  Install noise insulation tray → Rep. Gr.50.
–  Check headlight adjustment and correct if necessary → Booklet28
–  Carry out road test and read all fault memories → Chapter.
Torque settings:
   
Threaded connection Torque setting
Bolts, nutsM 610 Nm
 M 820 Nm
 M1045 Nm
 M1260 Nm
Deviations  
Front exhaust pipe to exhaust turbocharger25 Nm

   

Assembly mountings > < Securing engine to assembly stand