Engine Assembly Stand, Attaching Engine

Engine assembly stand, attaching engine

Note: To work on the engine outside of the vehicle, attach engine to assembly stand using the VW313 holding fixture along with the VW540 engine/transmission support.





Work sequence
- Transfer Engine/transmission subassembly to workbench via VAG1383A engine/transmission jack.
- Lower the engine/transmission assembly such that the transmission is supported.
- Remove lower engine/transmission connecting bolt.
- Push transmission off engine, while pushing the torque converter out of the drive plate.

Vehicles with automatic transmission
- Remove nut from torque converter.
- Clamp off ATF cooler hoses and disconnect at transmission cooler.
- Seal off transmission cooler using clean plugs.
- Secure torque converter to prevent it from falling out.





All vehicles
- Attach 2024A engine sling using 2024A/1 extension as follows and lift from VAG1383 engine/transmission jack using workshop crane:
^ Pulley end: 4th hole in hook at position 1
^ Flywheel end: 4th hole in hook at position 8

WARNING: Secure ALL hooks and locating pins with lock pins!

Note:
^ Positions marked 1 to 4 on the bar must be located toward the pulley end of the engine.
^ The holes in the hooks are counted up from the hook.

- Secure engine to holding fixture VW313 using VW540 engine/transmission support and VW540/1 supplementary kit.

Installation notes
Installation is reverse of removal, note the following during installation:
- Check whether centering dowels for engine/transmission are installed in the cylinder block, install if necessary.





- Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).

Vehicles with manual transmission
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft using G 000 100.
- Install hydraulic clutch slave cylinder:

Vehicles with automatic transmission
- Replace the lock washer on the selector cable anchorage.
- Install selector cable on transmission, adjust if necessary:

All vehicles
- When installing the engine and transmission assembly, make sure sufficient clearance to drive shafts.
- While raising, carefully guide the power steering fluid line past the transmission.





- Engine and Transmission subassembly is aligned transversely so there is a distance between engine mount -1- and engine bracket -2- of approximately 10 mm (installed condition).
- When bolting the mount support arm to the engine support and transmission console, the engine and transmission mount must not be stressed (aligned parallel to each other).
Tightening torques, Refer to Engine, Specifications, Mechanical
- Remove left-hand drive shaft and disconnect right-hand drive shaft at transmission:
- Remove front exhaust pipe.
- Remove connecting pipe between charge air cooler and intake manifold with EGR Vacuum Regulator solenoid valve.
- Install power steering pump:
- Electrical connections and routing:
- Install ribbed belt.





- Install sound dampening tray:
- Fill with engine coolant.