Engine, Securing to Engine Stand
Engine, securing to engine stand
Special tools and equipment
^ Engine and transmission support VW 540
^ Engine and transmission support supplement VW540/1 B
^ Lifting tackle 3033
^ Engine stand VAS 6095
^ Workshop crane VAS 6100
^ Not illustrated:
^ Bolt M12 x 160
Work sequence
^ Attach lifting tackle 3033 to engine and workshop crane VAS 6100 as shown in illustration.
^ Lift engine off engine bracket T101 02 using workshop crane VAS 6100.
^ Secure engine and transmission support VW 540 with parts from engine and transmission support supplement VW 540/1 B to cylinder block.
Note: Use the M12 x 160 bolt to secure the lower right arm (arrow).
^ Fasten engine to engine and transmission support VW 540 for assembly work.
Installing
Installation is performed in reverse order of removal. Note the following:
Note:
^ On assembly, replace the self-locking nuts and bolts tabs are tightened by turning through to a specified angle, as well as oil seals and gaskets.
^ Secure all hose connections with the correct type of hose clamps (same as original equipment), Refer to Parts Supplier.
^ Check whether dowel sleeves for centering engine/transmission assembly are installed in cylinder block; install dowel sleeves if necessary.
^ Bolt transmission to engine using new bolts.
Note:
^ Tightening torques only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
^ Additional lubricant such as engine oil or transmission oil may be used, but do not use lubricant containing graphite.
^ Do not use degreased parts.
^ Tolerance for tightening torques: + 15%.
Securing engine to transmission
A - dowel sleeves for centering
^ Install bracket -A- for bevel box; note following procedure:
- Initially tighten bolts -1- to 3 Nm.
- Tighten bolts -2- to 35 Nm.
- Tighten bolts -1- to 45 Nm.
^ Guide engine/transmission assembly into body.
^ Tighten bolts (use new bolts) for engine support to engine console (arrows)...
^ and transmission support to transmission mount (arrows) initially finger tight.
Note: The bolts are tightened to final torque only after adjusting the engine mountings.
^ Remove engine bracket T101 02 from engine.
^ Install axle shafts and tighten bolts hand tight.
Note: Axle shafts must be installed prior to further assembly.
^ Secure pendulum support at transmission (arrows -B-).Use new bolts.
^ Push engine/transmission assembly toward bulkhead. Journal of bevel box must be simultaneously inserted horizontally and carefully into flange of driveshaft.
CAUTION: The oil seal (arrow) in the flange of the driveshaft must no be damaged when installing the engine/transmission assembly. The driveshaft must be replaced if the oil seal is damaged.
^ Secure pendulum support at subframe (arrows -A-). Use new bolts.
^ Secure driveshaft with flexible coupling to flange of bevel box (arrows).
^ Tighten axle shaft bolts.
Perform further installation in reverse order. Pay attention to the following:
^ Install exhaust system and align it free of stress.
^ Install selector lever cable.
^ Install bracket for ancillary units.
^ Drive back respective bushings for securing bolts slightly to facilitate installation of Generator, power steering pump and A/C compressor.
^ Install Generator.
^ Install air conditioning compressor.
^ Install radiator cowl.
^ Install power steering pump.
^ Install body brace and cross piece.
^ Install poly V-belt.
^ Adjust engine mountings.
^ Connect electrical connections and check routing.
^ Connect Ground strap to battery.
^ Check oil level.
CAUTION: Never use the battery charging equipment for boost starting. There is a danger of damaging the vehicle control modules.
^ Fill cooling system.
Note:
^ Drained coolant may only be used again if the original cylinder head or cylinder block are reinstalled.
^ Contaminated or dirty coolant must not be used again.