Volkswagen Workshop Service and Repair Manuals

Installing engine Specified torques   Note t  Specified torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. t  Additional lubricant such as engine oil or gearbox oil may be used, but do not use lubricant containing graphite. t  Do not use degreased parts. t  Tolerance for specified torques is ± 15%.

Component			Nm
Nuts and bolts		M6	10
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:
Drive shaft heat shield to cylinder block			35

Gearbox to engine attachment

Item	Bolt	Nm
1	M12 x 55	80
2 1)	M12 x 150	80
3	M10 x 50	40
4	M12 x 60	80
5 2)	M6 x 8	10
A	Dowel sleeves for centralising
l  1) Also secures starter l  2) Cover plate for flywheel

Installation is carried out in the reverse order; note the following:   Note t  Renew bolts tightened through an additional specified angle. t  Renew self-locking nuts and bolts as well as gaskets, seals and O-rings. t  Hose connections as well as pipes and hoses of air channels must be free of oil and grease when installing. t  Secure all hose connections with the hose clips corresponding to original equipment → Electronic parts catalogue. t  Reinstall all cable ties in the same locations when installing.

–  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-.

–  If there are no dowel sleeves -A- in cylinder block for centring engine and gearbox, insert new ones. –  If clutch release bearing is worn, renew it → Rep. gr.30. –  Lightly grease gearbox input shaft splines with grease for clutch plate splines → Electronic Parts Catalogue. –  Check centring of clutch plate. –  Secure gearbox to engine. –  Guide engine/gearbox assembly into body. –  Install engine mount with new bolts.

–  Screw in engine mounting bolts -B- to contact initially by hand.

–  Screw bolts -A- and -B- for gearbox mounting into stop initially by hand.   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Install catalytic converter –  Install drive shafts → Rep. gr.40. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt: → Chapter. –  Install starter. –  Install front part of wheel housing liner. –  Connect coolant hoses with plug-in connector to heat exchanger for heater. –  Install washer fluid reservoir filler pipe with filler neck. –  Install clutch slave cylinder → Rep. gr.30. –  Install pendulum support → Rep. gr.34. –  Adjust assembly mountings → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery mounting and battery → Rep. gr.27. –  Install air filter housing → Chapter. –  Check oil level → Chapter.   Caution Danger of destroying control units through excessive voltage. Never use battery charging equipment for boost starting. –  Replenish coolant → Chapter.